04 Method Statement

JFE Engineering Corporation National Water Supply and Drainage Board
Contractor Employer Engineer’s Representative
Method Statement
CONTENTS
1. General ................................................................................................................................................. 6
1.1. Contractor’s Organization................................................................................................. 6
1.2. Project Scheduling ............................................................................................................ 8
1.3. Progress Report ................................................................................................................. 8
1.4. Sub-contracting ................................................................................................................. 9
1.5. Construction Mobilization ................................................................................................. 9
1.5.1. Mobilization for Temporary Facilities ............................................................................ 9
1.5.2. Mobilization for Construction Start-Up ......................................................................... 9
2. Design General Requirements ......................................................................................................... 10

2.1. General Approach to Design .......................................................................................... 10
2.2. Documents and Drawings for Submission to the Employer ....................................... 14
2.3. Review and Approval of Documents and Drawings ..................................................... 14
3. Material Procurement ........................................................................................................................ 17

3.1. Qualification and Selection of Suppliers, Manufacturers, and Subcontractors........ 17
3.2. Review and Approval of Materials and Equipment to be Used ................................... 19
3.3. Delivery Schedule and Reporting .................................................................................. 21
3.4. Transportation Plan and Export/ Importation Control ................................................. 21
4. Quality Control ................................................................................................................................... 23

4.1. Responsibility of Quality Control ................................................................................... 23
4.2. Design and Engineering .................................................................................................. 23
4.3. Materials Selection .......................................................................................................... 23
4.4. Manufacture of Equipment.............................................................................................. 24
4.5. Quality Control & Quality Assurance Manager ............................................................. 24
4.6. Lead Inspectors ............................................................................................................... 24
4.7. Inspection and Testing .................................................................................................... 24
4.8. Documentation and Quality Records ............................................................................. 24
5. Progress Control ............................................................................................................................... 25

5.1. Program Used .................................................................................................................. 25
5.2. Monthly Reports ............................................................................................................... 25
5.3. Project Photographs ........................................................................................................ 25
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Method Statement
5.4. Weekly Meetings .............................................................................................................. 25

5.5. As-built Drawings ............................................................................................................ 26
5.6. Progress Measurement Method ..................................................................................... 26
6. Safety and Risk Management ........................................................................................................... 30

6.1. General Cleanliness and Sanitation ............................................................................... 30
6.2. Working on Heights – Use of Scaffoldings and Ladders ............................................. 31
6.3. Working on Confined Spaces – Deep Tanks and Manholes ........................................ 31
6.4. Equipment Tools .............................................................................................................. 31
6.5. Excavation Work .............................................................................................................. 35
6.6. Crane Lifting Operation ................................................................................................... 36
6.7. Piling for Excavation Protection Work .......................................................................... 36
6.8. Rock Breaking/Excavation .............................................................................................. 38
7. Safety Plan ......................................................................................................................................... 38
8. Environmental Management Plan .................................................................................................... 38
9. Division of Works .............................................................................................................................. 38

9.1. Mechanical and Electrical Portion ................................................................................. 39
9.2. Pipeline Works ................................................................................................................. 40
9.3. Civil and Building Portion ............................................................................................... 40
9.4. Operation & Maintenance................................................................................................ 41
10. Work Methodology ........................................................................................................................ 41

10.1. Mechanical and Electrical Works ................................................................................... 41
10.1.1. Equipment Installation ............................................................................................ 41
10.1.2. General Plant Piping work ...................................................................................... 50
10.1.3. PVC Piping Installation Work ................................................................................. 64
10.1.4. General Pump Setting Work ................................................................................... 70
10.1.5. Submersible Pump Installation Work .................................................................... 72
10.1.6. Welding Works – Steel Pipes ................................................................................. 75
10.1.7. Electrical and Instrumentation Work ..................................................................... 83
10.1.8. Pre-commissioning and Trial Operation (Performance Test) ........................... 105
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Method Statement
10.2. Pipeline Works ............................................................................................................... 108

10.2.1. General Notes ........................................................................................................ 109
10.2.2. Pipe Laying Standards ..........................................................................................110
10.2.3. Manhole Standards ................................................................................................ 111
10.2.4. Other Pipeline Works Requirements ....................................................................112
10.3. Civil and Building Works ................................................................................................116
10.3.1. Scope of Work ........................................................................................................116
10.3.2. General Construction Requirements ...................................................................118
10.3.3. Specific Construction – Oxidation Ditch ............................................................ 121
10.3.4. Specific Construction – Sedimentation Tank ..................................................... 126
10.3.5. Specific Construction – Main Pumping Station ................................................. 129
10.3.6. Specific Construction – Effluent line and Outfall Structure ............................. 133
10.3.7. Specific Construction – Sludge Drying Bed Facility ......................................... 134
10.3.8. Standard Mitigating Measures – Impact of Construction ................................. 135
10.3.9. Mitigation Measures before and duringConstruction ....................................... 135
10.4. Operation & Maintenance (during Commissioning) ................................................... 143
10.4.1. General ................................................................................................................... 143
10.4.2. Commissioning Tests ........................................................................................... 144
10.5. Operation & Maintenance (during the Trial Operation/Performance Testing) ......... 145
10.5.1. Organization Chart for Operation & Maintenance ............................................. 145
10.5.2 Spare Parts and Special Tools for Operation and Maintenance....................... 146
10.5.3 Monthly Report and Daily Analysis ..................................................................... 148
10.5.4 Training Program................................................................................................... 148
10.5.5 Exit Test .................................................................................................................. 149
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Method Statement
METHOD STATEMENT
The following is the METHOD STATEMENT for the design works, construction installation works, and
pre-commissioning, trial operation and training schedules to be carried out by the Contractor (Bidder)
for Kandy City Wastewater Management Project particularly under Contract Package No. 1 – Design
and Construction of Wastewater Treatment Plant, Main Pump Station, Treated Effluent Disposal
System, Sludge Drying Beds and Supply of Operation and Maintenance Equipment.
The Contract will take part from the proceeds of the loan received by the Government of the
Democratic Socialist Republic of Sri Lanka from Japan International Cooperation Agency (JICA). The
Project will be administered by the National Water Supply & Drainage Board (NWSDB) under the
Ministry of Water Supply and Drainage (MWSD).
As provided in the Bid Data Sheet as Annex ITB-1, the Scope of Works to be provided by the
Contractor, are as follows:
Design, execute and complete the Works in accordance with the Contract and remedy any defect in
the Works of Wastewater Treatment Plant (WWTP), Main Pumping Station (MPS), Sludge Drying Bed
(SDB) and Main Force Line in the City of Kandy, Sri Lanka. Such Works comprises the following
Scope of Work:
a. Wastewater Treatment Plant
b. Main Pumping Station
c. Sludge Drying Bed
d. Force Main
e. Treated Effluent Line with Discharge Structure to Mahaweli River
f. Building Works
(i) Septage Preliminary Treatment Building at WWTP
(ii) Sludge Pump Building at WWTP
(iii) Disinfection Building at WWTP
(iv) Sludge Treatment Building at WWTP
(v) Administration Building at WWTP
(vi) Workshop & Garage at WWTP
(vii) Guard Post at WWTP
(viii) Main Pump Station Building at MPS
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Method Statement
(ix) Sludge Drying Bed Building at SDB

(x) Operation Building
(xi) Staff Quarters
g. Civil Works
(i) Grading Work for WWTP, MPS and SDB
(ii) River Protection of the areas of WWTP, MPS and SDB
(iii) Landscaping, Access Road, inside Road, Outside Lighting, Drainage and other
Ancillary Works
h. Supply of Spare Parts and Consumables
(i) Supply of Operation and Maintenance Vehicles, as specified
(ii) Supply of Mandatory Spare Parts of Mechanical and Electrical, as specified
(iii) Supply of Recommended Spare Parts of Mechanical and Electrical for 5 years
operation
(iv) Supply of Chemicals for the first six months period
(v) Supply of Laboratory Equipment and Tools, as specified
(vi) Supply of Workshop Equipment and Tools, as specified
(vii) Supply of Safety Equipment, as specified
i. Pre-commissioning, Trial Operation and Training
(i) Three months period of Pre-commissioning
(ii) Three months period of Trial Operation
(iii) One year Training for Operation and Maintenance Personnel
j. Provision of Services for the Employer and Engineer’s Representative
(i) Provision of Fully Furnished Employer’s Site Office
(ii) Provision of Fully Furnished Engineer’s Representative Office
k. All other items specified in the Employer’s Requirements – Bid Documents, Volume II.
This Method Statement establishes the execution program in the construction implementation. Work
procedures for all important activities planned to be carried out during the Construction Phase as
outlined here will be validated considering actual site conditions based on the verifications, tests and
surveys to be conducted during the Design Phase. In such case, adjustments or revisions will be made
if necessary.
Detailed method statements shall be prepared for specific tasks of the construction activities for which
as required shall be submitted at least 10 working days prior to commencement of relevant activity.
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Method Statement
Definition and Abbreviation
Following abbreviation and/or word shall be applied in this document.
(1) ”EMPLOYER” means National Water Supply and Drainage Board for Kandy City
Wastewater Management Project
(2) “JFE” means JFE Engineering Corporation of Japan as the Main Contractor
(3) “WORK” means Contract Package No. 1 – Design and Construction of Wastewater
Treatment Plant, Main Pump Station, Sludge Drying Bed and Main Force Line in the City
of Kandy in Sri Lanka.
(4) “WWTP” means inside the battery limit of the Wastewater Treatment Plant of the WORK.
(5) “MPS” means inside the battery limit of the Main Pumping Station of the WORK.
(6) “SDB” means inside the battery limit of the Sludge Drying Bed of the WORK.
(7) “OSBL” means outside of battery limit of WWTP, MPS and SDB.
(8) “JOBSITE” means construction jobsite for the WORK.
1. General
1.1. Contractor’s Organization

The proposed “Project Organization Chart” is provided under Attachment 7: Technical Proposal
Key Personnel for the Site Works Management shall be:
a. PM or Project Manager
b. CM or Construction Manager
c. AM or Administration Manager
d. QA/QC or Quality Assurance and Control Manager
e. DC or Design Coordinator
f. PE or Project Engineers for Designs, Civil Works, Installation Works and Pipeline Works
g. SO or Health and Safety Officer
h. EO or Environmental Officer
i. PCO or Project Control Officer
j. PRC or Procurement Coordinator
The Project Organization Chart with the Bio Data of Key Personnel is included in this Tender
submission that which forms part of the Contractor’s qualification.
In the execution of the WORK, the project site staff will be classified into functional teams.
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Method Statement
The Project Director (stationed in Japan Head Office) will be the leader of all teams and assisted
by the Project Manager and Assistant Project Managers to form the Management Team. The main
function of this team is to fully manage and control the WORK in all aspects. This is also the center
of decision making. All project site staff shall be fully accountable to this management team. And
one of their important is to closely coordinate with the Employer and the Engineer’s representative.
Discussions and meetings for problem tackling in regards with any important project matters will be
arranged with the Employer and Engineer’s Representative.
The Design Team will be handled by the Contractor’s Design Coordinator together with the
Engineers, Designers and experienced personnel. Design consultant firm particularly for Civil
Building and Structural Works will be employed to carry out the design activities though the Main
Process Designs including its Electro-Mechanical components will be an in-house participation. All
temporary and permanent works and their relevant details will be handled by this team.
The design will be produced in accordance with the submitted Time Programme. An important role
of this team is to coordinate with the design team of the Employer and the Engineer’s
Representative to ensure that the designs are matching each other and fully integrated.
The Control Team is formulated covering the Quality Assurance/Quality Control, Health, Safety &
Environmental and Project Control. This team is directly responsible to the Management Team and
to plan, implement and monitor the project in accordance to their respective special functions
assigned by the Management Team. Quality Assurance/Quality Control or QA/QC is responsible
for all the quality aspects including the material control, quality control and including drawing
control. Health, Safety & Environmental is responsible for the planning, training, implementation
and monitoring of all the health, safety and environmental aspects within the project. And the
Project Control is responsible for the planning and scheduling, cost control, quantity surveying and
contractual aspects.
The Construction & Installation Team is the frontline personnel to carry out the daily
construction and installation activities. This team is headed by the Construction Manager and his
Superintendents. They will coordinate and monitor the installation works as well as be responsible
for the daily coordination with the Employer and Engineer’s Representative on the site construction
issues. Being on the frontline, this team will be the prime mover of the project and they will be fully
responsible for a close and timely coordination all aspects of the WORK.
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Method Statement
The Services Team is assigned to assist the different teams in the project organization, especially
the Construction & Installation Team. This team is composed by the Engineering/Technical Section
under the Engineering Manager and the Commercial Section under the Administration Manager.
The Engineering/Technical Section will be responsible for the material & samples submission,
temporary works design & as-built drawings production and design coordination. While the
Commercial Section will be responsible in handling procurement, accounting, human resources
and administration issues within the project site.
1.2. Project Scheduling
The Overall Project (Master) Schedule will be submitted and discussed with the Employer for
finalization prior to implementation. Please see the proposed “Time Programme of Design and
Construction” under Attachment 7: Technical Proposal.
A Critical Path Method schedule shall be used to control the work of this Contract. Using Microsoft
Project software facilities, a project scheduling and monitoring shall be developed in the project
management of all phases of the WORK encompassing, but not limited to, general designs, site
surveys and investigations, detailed engineering, establishment of temporary works, periods of
manufacture, delivery, erection, construction, installation, setting of work, commissioning and site
testing of all works required including plant and civil works, pipelines and services.
The Time for Completion allowed for this Contract is 45 months reckoned from the Effective Date
from which the Contractor received the Notice to Proceed. It covers the 10 months of Design Stage
for the detailed design and engineering for which approvals should be obtained for the Preliminary
Design Report, Mobilization Report, Project Organization, Key Personnel and other preliminaries.
The Construction Phase follows covering the 29 months of construction and installation activities
and completed with the pre-commissioning tests in 3 months for a total of 32 months. The project
will be made final and complete with a 3 months of Trial Operation or Performance Test.
1.3. Progress Report
The Contractor will monitor progress of each activity on a daily and weekly basis, and this will be
summarized and submitted as a Monthly Progress Reports to the Employer throughout the entirety
of the design and construction of the project.
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Method Statement
The Monthly Progress Reports shall be submitted during the Project Meetings. This is to validate
the contents to the reports and to give the Contractor chance to bring about Project Issues and
Concerns. Coordination meetings, other regular meetings and even ad-hoc meetings will be taken
into consideration to support the progress monitoring of the project.
1.4. Sub-contracting
The Contractor might use Local Contractors in Sri Lanka shown in “Attachment 6 the list of
Subcontractor and Vendor List”, to perform all of the Civil Works, as well as part or whole of
specific items if necessary. These contractors will be under the supervision of the Contractor to
ensure safe, quality and prompt delivery. Installation Work will be done by the Contractor.
1.5. Construction Mobilization
1.5.1. Mobilization for Temporary Facilities
As provided in the Bid Documents Volume I – Instruction to Bidders and Conditions of Contracts
under Annex C, Sub-Clause 2.1, it states that the ‘Time for Access is 150 days after the
commencement date.’ This is approximately 5 months after the commencement into the Design
Phase.
Mobilization of resources will follow the required Time for Access. Preliminary works such as
topographic surveys, geotechnical investigations, test pits and other necessary preliminary studies
will be commenced at this stage. Results of these preliminary works will be used to validate the
preliminary designs and make final the detailed project designs.
Likewise, mobilization for temporary works such as setting up of Contractor’s Field Office,
Engineer’s Field Office, site construction access, site construction utilities, and other temporary
facilities will be initiated. Manpower and equipment mobilization will follow the planned Overall
Construction Program to be presented in the Pre-Construction Conference.
1.5.2. Mobilization for Construction Start-Up
The construction phase begins after the 10-month Design Phase for which the project design has
been approved and the construction permits have been obtained.
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Method Statement
The mobilization period within the construction phase shall be for the purpose of attending to the
following tasks and obtaining the required approvals, and also for making required preliminary
work for the efficient construction program.
(1) Obtaining approval of the detailed design report
(2) Obtaining approval for project organization structure of the Contractor and supervisory
arrangements
(3) Obtaining approval for Bio data of key personnel to be deployed
(4) Obtaining approval for local or foreign sub-Contractors if any
(5) Organizing required insurance, agreements with local agencies etc.
(6) Confirmation of work schedules
(7) Establishing mechanisms for liaison with external agencies (Kandy Municipal Council,
Mahaweli Authority of Sri Lanka, Roads Development Authority, Sri Lanka Telecom Ltd,
Ceylon Electricity Board, Local Authorities and Central Environmental Authority, etc.)
(8) Obtaining EMPLOYER’s assurance and commitments for land acquisition, power supply,
road approvals, source, environmental clearances, etc.
(9) Preparation and submission of a Mobilization Report including necessary documents,
agreements, method statements, etc. for review and approval of the ENGINEER
(10) Construction Officers for the Engineer’s Representatives and Employer’s Project
Management Unit
(11) Providing Transportation for PMU and Consultant’s Staff
2. Design General Requirements
2.1. General Approach to Design
Design Data Validation and Site Surveys – Review of Preliminary Design
After award of the contract, all provided survey data, soil investigation reports and technical reports
shall be verified and further investigation and topographic survey will be carried out as necessary
during the 10-month Design Phase. The layout plans received with the tender documentation
have indicated the setting out plan for structures and pipe lines. These data have been used for
the preparation of the bidder’s proposals and it shall be the responsibility of the Contractor to verify
them for any inaccuracies, errors or omissions in the information provided.
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Method Statement
A new topographical survey, based on nodal points taken from the concept hydraulic designs, will
be conducted purely to verify the data provided and to correct the location and elevation of
structures that are to be considered for preliminary designs. The proposed topographic survey will
cover the entire project sites of WWTP, MPS and SDB.
This survey will also establish the Temporary Bench Marks (TBMs) for the construction and
installation teams and will provide relevant details of existing structures such as bridges located
along the trace of the proposed gravity and force sewers. Slight adjustments of the force main pipe
trace will have to be made to suite site conditions and for the setting out of pipe trace and new
structures.
The geotechnical investigation report will be studied along with the topographic information and
where necessary further investigation shall be carried out to acquire soil characteristics for
foundation designs of treatment plant, lifting station and other structures.
A provisional sum has been allocated in Bill of Quantities, Bill #1-Preliminaries, Item 20, for further
investigation and additional topographical survey work such as this.
After the review of preliminary design and prior to the commencement of detailed designs, the
Contractor will submit a report to the Engineer on the outcome of review and data verifications.
Detailed Design
Detailed design shall be carried out in consideration with conforming to the agreed design criteria
and its requirements and specifications, specifying the durability of structures, pipes, plant and
equipment, taking into account for energy-efficient equipment and conforming to engineering best
practices for energy conservation in the design of the treatment plant, pumping station and building
systems. During the Design Phase, the General Design Informationwill be prepared and shall be
submitted to the Engineer for review.
Involvement and participation of the wastewater O&M staff shall likewise be arranged during this
phase to obtain valuable inputs and feedbacks on the design of the facilities.
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Method Statement
Civil, Building and Structural Designs
Civil, building and structural designs will be carried out hand in hand with mechanical and electrical
designs of pump house, treatment plant and its facilities, sludge drying beds, pipelines, outfall
structures, as well as development plans for access road, river protection and others. The
engineering design shall comply with the design criteria and design standards given in section 4 of
the general requirements. Sewer system design shall also comply with Design Manual D7 and the
design criteria. All civil structures shall comply with the relevant sections of BS 8110, BS 8007
and BS 8005.
Sub-structures within groundwater shall be protected from buoyancy and designed to withstand
buoyancy effects and static loads. During construction, the uplift due to buoyancy is to be
neutralized by introducing balancing loads with sand or soil bags.
A minimum period of six weeks is required after approval of the design of structures and its
respective drawings and schedules prior to commencement of construction. This arrangement
shall accommodate within overall construction period and has no impacts on construction
programs.
Main Pumping Station
The civil designs for pumping station shall comply with the requirement given in Section 5.0 of
Particular Specifications. Wet well type sewage lifting station will be constructed using concrete
made with sulphate resisting cement. The size of wet well is determined according to the number
of stops. It is recommended that 10 stops per hour be allowed for, for submersible pumps.
This pumping station will be equipped with an automatic grit removal system and a manual
screenings removal system. The total head of the pumping system is less than 15m in the pumping
station.
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Method Statement
Force Main Pipeline
The preliminary design shall comply with requirements given in Section 5.0 of the particular
specifications. DI [PN16] pipes are proposed for the pumping mains. Tyton joint will be adopted
for the system connections and where specified, expansion joints shall be provided. Thrust blocks,
specials, and valve details are all given on drawings. All pipes above ground shall be DI flanged
type.
The force main pipeline design will provide a design for surge pressures using appropriate surge
analysis computer software and the necessary control measures. Hydraulic design calculations
including hydraulic profile study will likewise be included in the detailed design of the force main
pipeline.
Mechanical – Electrical Designs
Mechanical and electrical detailed designs will be reviewed and submitted hand-in-hand with the
civil design. The components are designed to BS or equivalent standards acceptable to the
Engineer to consider all aspects in the installation, testing and commissioning of all mechanical
and electrical equipment and all other items necessary for a complete and functional installation fit
for the intended purposes at each site – wastewater treatment facilities, main pump station, sludge
drying, and all buildings/quarters.
On completion of the first part of the design, it will be submitted to the Engineer for approval.
Necessary revisions to the design, to suit site conditions, shall be carried out during the
construction period.
Design activities that will be carried out, but are not limited to, are:
a. Preparation of process design arrangement of process units and connections.

b. Preparation of drawings and documentation.
c. Necessary revision of technical designs according to the requirements of the Engineer.
d. Preparation of detailed drawings for equipment and mechanical installation.
e. Preparation of materials list and supplies list.
f. Preparation of detailed technical documentation.
g. Preparation of O&M manuals and operation principals.
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Method Statement
2.2. Documents and Drawings for Submission to the Employer
Documents, such as Project Schedule, Progress Reports, Design Computations, Material

Specifications, Catalogues, Brochures, Samples, as well as Drawings, such as Process Flow
Diagram, Plant Layout, Piping and Instrument Diagram, and Civil and Building Drawings, will be
submitted to the Engineer. The submission of which shall be based on the Document Submission
Schedule which will be mutually agreed upon by Employer, Engineer and Contractor after
Contract. Contact Point and Address is shown below.
All contact point correspondence shall be addressed as follows:
EMPLOYER
Attention :
Address :
Phone No. :
FAX No. :
e-mail :
Project Manager as Contractor Leader assigned by JFE Engineering Corporation

Attention :
Address :
Phone No. :
FAX No. :
e-mail :
2.3. Review and Approval of Documents and Drawings
The Engineer, within a reasonable time after receipt of any document or drawings for approval
from the Contractor, will either return the document or drawing to the Contractor with the
Engineer’s Approval or will notify the Contractor in writing of his disapproval and the reasons
behind the disapproval. No work will proceed without the written approval of the Engineer.
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Method Statement
1) Correspondences between Employer, Engineer and the Contractor

All of correspondences between Employer, Engineer and the Contractor shall be executed as
following procedure.
(1) LETTER or TRANSMITTAL

“LETTER or TRANSMITTAL” shall be used with reference number when the matter that each
party should tell the opponent is caused.
Also, it can be used as document transmittal sheet when drawings and/or documents should
be sent.
(2) NOTICE / INFORMATION and QUERY

Any notice and/or information and queries shall be sent by facsimile, and/or converted PDF
file via e-mail.
(3) DOCUMENT TRANSMITTAL

Any technical drawings and documents shall be attached to latest “DRAWING &
DOCUMENT LIST” with “LETTER or TRANSMITTAL” and shall be sent by courier.
For the purpose of notification of submission, first page of the letter shall be sent by facsimile
and/or e-mail in advance.
(4) ACKNOWLEDGEMENT OF RECEIPT

Recipient of each party shall notify the sender by facsimile after signing the first page of the
letter immediately.
(5) REPLY TO THE COORESPONDENCES

Person in charge of each party shall reply the counterpart within 10 working days from the
receipt or by specified day in the letter.
The Contractor shall monitor the submission status of LETTER or TRANSMITTAL using log
sheet as appropriate.
(6) MINUTES OF MEETING

MINUTES OF MEETING shall be provided at each meeting. All decision or instruction
involving change or exemption from specification or other important subject made at the
meeting shall be mutually confirmed in the minutes of meeting.
.
The Contractor shall monitor the submission status of minutes of meeting using log sheet.
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Method Statement
(7) E-MAIL COMMUNICATION

Other communication between each counterpart could be applied by e-mail according to the
below rule.
-CC to each project manager shall be required.
-Reply to all addressed members shall be required.
2) Format of Technical Drawing and Document

(1) Numbering System
The numbering system of all drawing and document shall depend on the following
numbering system accordingly.
Example
② Kinds of document
D : Shop Drawing
S : Sample
M : Manual
I : Information
〇－〇〇〇〇〇－〇〇－△
⑥ Revision No.
The first issued document is “A”.
⑤ Serial Number (01-99)
④ Section Number
The Contractor will submit the coordination of procedure immediately after receiving notice to
proceed. Technical drawing and document will be monitored/ controlled by DRAWING &
DOCUMENT LIST to be provided later.
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Method Statement
(2) Title Block of Technical Drawing - Following figure is example of typical title block.
APPD CHEKD CHEKD CHEKD DRAWN Date
(Name) (Name) (Name) (Name) (Name) SCALE
FOR (Client’s Name)
JOB TITLE xxxxxxxxxxPLANT
DWG TITLE GENERAL ASSEMBLY DWG FOR xxxxxxx
JOB CODE DOC.NO.
(Each Company’s Name)
(3) Cover Sheet of Technical Document
Cover sheet of technical document shall be followed this document.
(4) File name of Electrical Data

File name of electrical data shall have the number, revision number and the name. For
example, “PE2-02001-Rev.1 (COORDINATION PROCEDURE).doc”
3. Material Procurement
3.1. Qualification and Selection of Suppliers, Manufacturers, and Subcontractors
Material procurement will be made from suppliers, manufacturers, and subcontractors who offer
reliable goods and work performance. Qualification and selection is done based on the criteria of
the Contractor. Conformity to required specifications is required prior to placing of purchase
orders.
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Method Statement
The Procurement principle applies to procurement and its related works for such as overseas and
inland transportation required equipment, materials and its spare parts to the storage area of the
JOBSITE.
The information of Vendors and/or suppliers and submitted by the prospective bidders listed in
“BID C 8.Proposed Subcontractors for Major Item of Plant and Installation Service”.
Sufficient qualified personnel shall be assigned to plan, manage, document, monitor, and report
procurement activities. Equipment and material shall meet or exceed the project requirements for
quality. Deliveries shall meet the construction schedule.
Important formalities (Laws, regulations and instructions of the government) if applicable, for
equipment and materials, shall be observed.
1) Procurement Organization
All procurement activities, to be executed at the ContractorHead Office, are managed by the
Purchasing & Logistic Manager (PLM) independently. PLM is supported by staffs in
Procurement Department. Project QA/QC manager (QA/QCM) will also support PLM in the
coordination of required Inspectors to be carried out on Materials and Equipment.
2) Procurement Process
Inquiry to Vendor and/or Suppliers
The Contractor shall issue Request for Quotations (RFQ) to nominated vendors and/or
suppliers, which consists of the following documents.
(1) Requisition including technical specification and/or drawings

(2) Commercial terms and condition on Purchase Order
(3) Quality control/Inspection instruction to vendor and/or supplier
(4) Packing and shipping instruction to vendor and/or supplier
(5) Vendor and/or supplier print instruction
(6) Requirement for vendor’s and/or supplier’s technical service (if applicable)
(7) Secrecy Agreement (If required)
(8) Other requirements on the project, if any
3) Evaluation of Suppliers Quotations

Upon receipt of quotations from vendors and/or suppliers, the Contractor shall proceed with
clarification and evaluation in technical and commercial aspects.
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Method Statement
While it is mandatory that equipment and materials quoted by vendors and/or suppliers are of
good quality, conform to the Project technical requirements and meet the requested delivery
time, the following points are also confirmed and considered in Contractor’s evaluation;
(1) Dimension and weight of equipment with regard to transportation, layout and installation
(2) Ease of installation, operation and maintenance
(3) Vendor’s and/or supplier’s experience/historical record on supply of similar equipment
and materials
(4) Lessons learned with vendors and/or suppliers and for similar equipment/materials
(5) Vendor’s and/or supplier’s Quality Assurance and Quality Control System/Organization
(6) Quality/Capacity/Inventory of vendor’s and/or supplier’s fabrication facility and equipment
including annual production capacity, work space (indoor/outdoor), and manpower
information (design, shop, QA/QC, field etc.)
(7) Current and future shop load & backlog of vendors and/or suppliers
(8) Vendor’s and/or supplier’s after sales support/service system/organization
(9) Acceptability of deviations/exceptions proposed by vendors and/or suppliers from the
project commercial terms and conditions, particularly on the warranty, liabilities and
indemnification
(10) Source of suborder materials and/or name of sub vendors and/or suppliers
(11) Payment terms and conditions proposed by vendors and/or suppliers
(12) Vendor’s and/or supplier’s financial stability
(13) Vendor’s and/or supplier’s proposed conditions for field technical service, if applicable
(14) Spare parts for construction, commissioning, start-up and operation, and special Tools
(15) Requirements for the Contractor’s resident personnel (engineer, expediters, inspectors)
during design and fabrication
After evaluation, the Contractor will choose recommended suppliers for review and approval by
the Engineer.
3.2. Review and Approval of Materials and Equipment to be Used
Material Specifications, Catalogues, and Brochures will be submitted by Contractor to the

Engineer for Approval. No material will be purchased without the written approval of the
Engineer. After the Engineer’s approval, procurement products shall be commenced as follows.
1) Placement of Purchase Order

After evaluation of vendors and/or suppliers, the Contractor places purchase order with his
vendor and/or supplier.
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Method Statement
If changes in the specification, the quantity, delivery date arising from Contractor’s/vendor’s
and/or suppliers reason and so on occur after placement of the original purchase order, the
Contractor settles cost and schedule impact with the vendor and/or supplier and issues a
supplemental purchase order to them accordingly.
Any changes to the original Purchase Order arising from other stakeholder’s (e.g. EMPLOYER,
AUTHORITY) reason shall be covered by change orders to reflect the change to both technical
and commercial.
2) Meeting with Vendor or Supplier

For critical and major equipment, the Contractor will hold Kick-Off Meeting with the vendor
and/or supplier at the Contractor’s office soon after order placement. This is to ensure that the
Contractor’s requirements and instructions on the technical specifications and design details,
shipping are fully understood by the vendor.Vendor’s organization for the Project and vendor’s
and/or supplier’s schedule/plan on engineering drawings/data required for Contractor’s review,
sub-orders, fabrication, inspection/testing and expediting control level are also will be confirmed
in detail.
And also for critical and/or major equipment, the Contractor will hold Pre-Inspection Meeting
with the vendor at the vendor’s shop, at which time the requirements and procedures for
inspection/testing are confirmed in detail.
3) Progress Monitoring and Expediting

The Contractor carries out progress monitoring and expediting purchase order activity and the
work of its vendors of all tiers, to ensure that quality, technical, and schedule requirements and
objectives have being met.
The Contractor shall be solely responsible for the expediting of deliverables from vendors
and/or suppliers to Contractor and for their return to vendors and/or suppliers in a timely
manner. The Contractor shall also be solely responsible for expedition suppliers so that
materials are delivered in accordance with purchase order requirements and project schedule.
4) Procurement Quality Control

It is the responsibility of the Contractor to ensure that standards of materials and services are to
project standards regardless of the source.
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Method Statement
Inspection and Test for procured equipment and materials are carried out by Quality Control &
Quality Assurance Section and approved Inspection Agencies in accordance with designated
Inspection Level defined in the relevant requisition control of QC/QAM.
The vendor is not allowed to fabricate till the Contractor reviews the vendor’s Inspection and
Test Plan (I&TP), Test Procedures, WPS/PQR, General Assembly drawings.
In accordance with the reviewed I&TP, the Contractor proceeds with the inspection activities
such as:
(1) To obtain the inspection applications and monthly inspection schedule from the vendor
(2) To review inspection and test records obtained from the vendor
(3) To witness the vendor’s inspection and testing and to report the result to all concerned
parties
(4) To issues inspection release notices to the vendor before the equipment and materials
are to be packed for shipping
Where necessary, the Contractor takes the following action:

(1) To request the vendor to take corrective action, if the result of inspections was found to
be unsatisfactory
(2) To inform upon situations relevant stakeholder
3.3. Delivery Schedule and Reporting
The Contractor will submit a Comprehensive Material and Equipment Delivery Schedule to the
Engineer. Monitoring of which will be done regularly. Test and Inspection of Materials and
Equipment will be done before delivery, according to the criteria of the Contractor. Copies of Mill
Certificates, Test Certificates, and Inspection Checklist will be submitted by the Contractor to the
Engineer for reference and record. All activities here will be performed according to ISO9001
Standard (Quality) Manual and Project Specifications.
3.4. Transportation Plan and Export/ Importation Control
The Contractor will be responsible for organizing, coordinating and performing all arrangements
for the transportation of goods procured to the storage area provided. The Contractor will
produce individual shipping manuals/ procedures for the transport of critical equipment, if
necessary. The Contractor will arrange all appropriate transportation for the cargoes through the
nominated international freight forwarder.
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Method Statement
1) Export Packing
The Contractor will request the supplier or international freight forwarder for export boxing
and ensure that all packing for materials and equipment is suitable for transport from
Supplier’s Warehouse up to arrival at the site. Packing should be adequate to withstand the
adverse effects of rough handling at the ports of embarkation and destination and during sea/
airfreight. Any goods received damaged will be repaired or replaced by the Contractor.
2) Shipping
The Contractor will request the Supplier or international freight forwarder for preparation of
shipping documents for import customs clearance. These documents will be prepared in
strict compliance with the Contractor’s instructions. The consignee shall be the EMPLOYER.
Subject to construction schedule constraint, consolidated shipment of multiple cargoes from
various vendors will be considered for the following reasons:
(1) To avoid loss of small cargoes in transit,
(2) To avoid minimum inducement charge which the shipping company in case the actual
shipping volume per vessel was less than the agreed minimum volume, and
(3) To secure enough storage space on the vessel for the cargoes.
Pre-shipping advice upon booking on the vessel and final shipping advice after
departures of the vessels will be issued by the Contractor’s international freight forwarder
to all concerned parties. The international freight forwarder distributes the shipping
documents for import customs clearance to all concerned parties as well.
3) Customs Clearance
The Contractor will ensure that all shipping invoices include the Brussels Tariff Nomenclature
Number (BTN), Harmonized Tariff Schedule or equivalent. The Contractor will bear full
responsibility of all shipping documents. After arrival of the vessel on international Vietnam’s
port, the local freight forwarder will arrange unloading the goods from the vessel, and arrange
for the customs clearance.
4) Inland Transportation to the Jobsite

After the customs clearance, the Contractor will arrange inland transportation for the goods to
the storage area provided.
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Method Statement
5) Unloading at the Site

The Contractor will be responsible for organizing, coordinating and performing all unloading
and storage arrangements at the site.
4. Quality Control
4.1. Responsibility of Quality Control
The Contractor is responsible to control the quality of work and complete the work in accordance
with the Contract. The Contractor will provide all labour, materials, and equipment necessary to
achieve this. The Contractor will have and maintain a Quality Control System that complies with
ISO9001 or an equivalent Quality Management System that is acceptable to the Employer and to
the Engineer. Although registration for ISO9001 is not required, a Quality Management System
will be implemented. The Contractor will submit documentary evidence of compliance with all
Contract Requirements ensuring that all activities related to Quality Control are being applied.
4.2. Design and Engineering
Design and Engineering will be performed by Qualified Engineers having sufficient knowledge
and experience with similar plants and projects. Designs and documents prepared by these
engineers will be further reviewed by other specialists of the Contractor during the Design Review
Meeting to further enhance it and prevent the possibility of error and to eliminate the risks
involved because of this inaccuracy. A Complete Set of Design and Engineering Documents will
be submitted by the Contractor to the Engineer for approval before any construction,
manufacture, and procurement will commence.
4.3. Materials Selection
Materials to be used will be selected from commercially available materials based on

procurement experience of the Contractor. Required Specifications were clearly given in the
drawings and engineering documents. However, no material will be purchased without the written
approval of the Engineer. Special materials for critical use will be carefully inspected by the
Contractor to determine if they comply with the required material specification before manufacture
and delivery to site.
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Method Statement
4.4. Manufacture of Equipment
All equipment designed by the Contractor will be manufactured by qualified suppliers selected
under specific qualification criteria. These suppliers should have previous experience in providing
equipment to the Contractor. On the other hand, simple equipment will be supplied by local
suppliers in Sri Lanka. Inspectors will be appointed by the Contractor and dispatched to every
manufacturing plant to check the quality and ensure that the required specifications are being
met.
4.5. Quality Control & Quality Assurance Manager
The Contractor will assign a Quality Control & Quality Assurance Manager who will be
responsible for overseeing the overall Quality Control Plan of the Contract.
4.6. Lead Inspectors
The Contractor will assign Lead Inspectors for each shift for each location where work is being
performed. Each Lead Inspector will be chosen based on his qualification, training, and
experience in all construction activities being conducted at his assigned location of work.
4.7. Inspection and Testing
The Contractor will notify the Employer and the Engineer in writing of all inspection and testing
activities. All materials, equipment, and works will be inspected and tested in accordance with the
Quality Control Planto verify that they follow the Method Statement, Work Specification, and
Construction Drawings. Documentary records and evidences will be maintained of all inspections
and tests conducted.
4.8. Documentation and Quality Records
The Contractor will keep document, collect, and preserve records of all activities performed for
the Contract. Documents will be prepared in forms acceptable to the Engineer. Quality Records
will be provided and maintained in accordance with the Quality Control Plan. The Contractor’s
Quality Control & Quality Assurance Manager will provide, as part of the Monthly Progress
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Method Statement
Report, a monthly written certification that the Quality Control Plan and all of its measures and
procedures are functioning properly and being complied with.
5. Progress Control
5.1. Program Used
Initial and all subsequent programs will be in such forms that the critical element of construction
can be readily identified. The application of computer techniques is considered essential. The
program will be based on the application of established programming procedure such as Critical
Path Analysis (CPA) and Program Evaluation and Review Technique (PERT). All programs will
show the expected cash flow both monthly and cumulatively.
5.2. Monthly Reports
The Contractor will submit a Monthly Report showing the Actual Progress against Scheduled,
Actual Ordering and Delivery Dates of Materials and Equipment versus Anticipated, Information
required by the Contractor from the Employer and the Engineer, and Plant, Labour, and Materials
on Site at the end of the month. Monthly progress will be marked on sets of Construction
Drawings kept specifically for this purpose. Important dates and the like will also be recorded on
these drawings.
5.3. Project Photographs
The Contractor will provide the Engineer technically perfect coloured photographs of the Works
taken in such manner and time as the Engineer directs.
5.4. Weekly Meetings
Regular weekly meetings, the time and day as agreed upon by both Contractor and Engineer or
his representative, will be held to examine actual progress against agreed program.
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Method Statement
5.5. As-built Drawings
The Contractor will progressively prepare As-built Drawings covering all of the works based on
the Construction Drawing and a Final Report.
5.6. Progress Measurement Method
Overall progress measurement method is illustrated as follows:
ENGINEERING PROCUREMENT CONSTRUCTION&

PRE-COMMISSIONING
PROGRESS PROGRESS PROGRESS
Weight Factor Weight Factor Weight Factor

XX% YY% ZZ%
OVERALL
PROGRESS
1) Engineering Progress
(1) Measurement Unit and Identification
Engineering progress is measured in integration of key progress documents expressed in
the DRAWING AND DOCUMENT LIST.
(2) Engineering Progress Weight %

The following weight percent figures for each discipline are based on the estimated the
value is applied for measurement of progress per each document and task.
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Method Statement
Ex.)
DWG & DOC Weight %

Overall Each
TOTAL 100% 100%
(3) Milestone for Engineering Progress

Each documentation work is monitored and measured by the following milestones.
Ex.)
Start Issue to Approval Issue as

EMPLOYER from EMPLOYER the Contractor’s
for Approval Final Design
20% 30% 30% 20%

Cumulative Cumulative Cumulative Cumulative
20% 50% 80% 100%
2) Procurement Progress
Procurement progress is measured in integration of principal equipment (and materials)
for WWTP.
(2) Procurement Progress Weight %

The following weight percent figures for each item are based on the budgetary amount of
the price of equipment and materials are applied for measurement of progress per each
equipment and materials.
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Method Statement
Ex.)
EQUIPMENT AND MATERIALS Weight %
Overall Each
Equipment ---
Machinery (e.g. Pump) ---
Local Fabricate Equipment ---
Electrical ---
Power receiving Unit ---
Panel ---
Instrument ---
Monitoring, Control and ---
Automation System
Field Instrument ---
Pipe with components ---
Embedded Piping w/Fitting ---
Piping w/Fitting ---
Valve and components ---
Cables
TOTAL 100% 100%
(3) Milestone for Procurement Progress

Each procurement activity is monitored and measured by the following milestones.
Ex.)
Requisition L/I and/or P/O Witness Ex-Works*2 or Arrival at
issue Inspection arrival at Sri JOBSITE
to Vendors Ex-Works*1 Lanka Port
10% 20% 50% 10% 10%
Cumulative Cumulative Cumulative Cumulative Cumulative
20% 30% 80% 90% 100%
NOTE : 1. Ex-Works*1 will be applied for items that have no witness inspection.
2. Ex-Works*2 will be applied for items fabricated at Sri Lanka.
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Method Statement
3) Construction Progress
Construction progress is measured in integration of major construction progress for STP.
(2) Construction Progress Weight %

The following weight percent figures for each activity are based on the construction and
installation schedule are applied for measurement of progress per each activity.
Ex.)
Construction & Weight %
Installation Overall Each
Civil Work 46%
Architecture Work 7%
Mechanical Work 17%
Electrical Work 10%
Sewer Pipe Work 20%
TOTAL 100% 100%
(3) Milestone for Construction Progress

Each Construction and Installation are monitored and measured by the following
milestones.
Ex.)
Wastewater Treatment Plant Pumping Station
Civil Works AR ME E&I CW Others
SW ST Others
13% 25% 2% 7% 15% 10% 6% 2%

Cumu- Cumu- Cumu- Cumu- Cumu- Cumu- Cumu- Cumu-
lative lative lative lative lative lative lative lative
13% 38% 40% 47% 62% 72% 78% 80%
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Method Statement
Where:
SW – Site Works
ST – Structural Works
AR – Architectural Works
ME – Mechanical Works
E&I – Electrical and Instrumentation Works
6. Safety and Risk Management
Having regarded with an utmost priority, safety and risk management for the construction works
will be implemented in compliance with the Contractor’s Project Health, Safety and Environmental
Management Plan (as provided in Section 7 of this Method Statement) in accordance with all the
relevant Sri Lankan health, safety and environmental regulations.
Where necessary and as outlined in the Project Health, Safety and Environmental Management
Plan, Safety Job Analysis and Risk Assessment are provided for those elements of the each
critical construction activity identified as being a risk factor. Impact of risk is assessed and
quantified in terms of project cost, construction schedule and work quality. Treatment of these
risks is mainly to provide control by avoidance and impact reduction. Outlined here but not
necessarily limited as listed below are some of major areas for which safety and risk assessments
will be taken as part of the implementation of the Work.
6.1. General Cleanliness and Sanitation
The Project Construction Sites – the Wastewater Treatment Plant Area, the Main Pump Station
Area in Getambe, the Sludge Drying Bed Area, the New Operations Building and the several Staff
Quarters – are to be kept clean at all times. Regular cleaning schedule will be setup with the
implementation of standard housekeeping requirements such as garbage disposal, construction
waste management, and sanitation maintenance program.
Work personnel will be monitored to maintain good hygiene standards with regards to their camp
accommodation, mess areas, latrines, shower/wash areas, and the required personal protective
equipment such as uniforms, hard hats, safety shoes, body harness, goggles, era plugs, dust
masks, gloves, and others.
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Method Statement
6.2. Working on Heights – Use of Scaffoldings and Ladders
In the erection of scaffoldings and construction work staging platforms, safety regulations and
standards are to be followed. Only qualified scaffolders or erectors are to be allowed to conduct
such work.
Erected scaffolding and construction work staging platforms shall be checked by the qualified
scaffold checker and safety officer prior to its use. It shall be erected complete with hand rails,
protected work platforms, toe boards, life lines and protection netting, where necessary.
All ladders shall be ensured to be firmly secured at the foot and at the top and should have stiff
members to avoid swinging. Ladders exceeding 4 meters in height shall be secured at midpoint.
And ladders should be on a clear area and within easy reach of the workplace.
6.3. Working on Confined Spaces – Deep Tanks and Manholes
Working on confined spaces such as deep tanks, manholes or the likes shall require a full body
safety harness to be worn at all times. Workers inside the confined spaces shall be roped to the
exit point at all times using life line attached to their safety harness. Fresh air circulation using air
blowers and exhausts shall be ensured inside the confined spaces or chambers to avoid
suffocation.
In the event of an incident that rescue is necessary, only qualified rescue crew shall be allowed to
conduct rescue operation. Use of breathing apparatus, retriever (crane or tripod and winch), gas
detection equipment and other safety tools shall be used as may be required.
6.4. Equipment Tools
1) Equipment, Instruments, and Appliances of Convenience

(1) Unsafe Equipment
a. Any electric or battery powered equipment or appliances of convenience such as
radios, CD players, hand phones, etc., that are non-intrinsically safe will not be
permitted in hazardous areas where there are potential hazard of flammable gases,
vapours, and fumes.
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Method Statement
b. Non-intrinsically safe laboratory analytical instrument will not be used unless prior
approval has been obtained in the form of a work permit.
(2) Engine Driven Equipment
a. All engine driven equipment whether installed on vehicles or not, such as auxiliary
machinery, pumps, welding machines, compressors, etc., shall be fitted with spark
arresters when used in areas with potential hazard of flammable gases, vapours, or
fumes. Prior approval shall be obtained before using them.
2) Electrical Equipment
(1) Any electrical equipment which does not form part of the fixed installation of the plant is
considered as portable, transportable, or mobile equipment, will be of the approved
types:
a. Hand amps
b. Welding sets
c. Mobile generators
d. Portable tools
e. Flexible cables
f. Temporary switchboards
g. Motorized tools or equipment
h. Battery and battery operated tools
i. Hand phones
j. Transceiver sets
k. Etc.
(2) All electrical equipment will be checked by the Electrical Section before they can be used.
(3) All electrical works shall be conducted in accordance to statutory requirements.
(4) Only trained and experienced electricians will perform electrical works.
(5) No one will change, alter, or modify any electrical equipment, tools, or instruments except
authorized electricians.
(6) The user shall also conduct visual inspection of his electrical equipment tools and
instruments each time before use.
(7) All hand tools and hand amps are to be checked and tested by competent electricians
before they can be used.
(8) All hand torches used in areas with potential hazards must be of the intrinsically safe
construction type.
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Method Statement
(9) All live parts of temporary electrical installations and equipment shall be effectively
guarded.
(10) Electrical plugs and sockets must be of distinctive type to ensure that no connections can
be affected by sudden change in voltage. They must conform to the local electrical
standards.
(11) Warning signs or posters, such as “DANGER, HIGH VOLTAGE”, “NO ENTRY – EXCEPT
AUTHORIZED PERSONS ONLY”, etc., shall be displayed as and when necessary during
work and at dangerous areas such as substations, switchboxes, overhead or
underground cables, etc.
(12) Periodic inspection and maintenance of electrical installations and distribution systems
will be carried out at least once a month by a competent person or licensed electrician.
(13) All portable equipment, tools, and instruments will be used with ELCB to protect workers
from electrical shocks or electrocution.
(14) All electrical used in site will be maintained in good working conditions at all times.
(15) Equipment that causes arcing or sparking will not be used until it is properly repaired by
authorized electricians.
(16) All electrical hand tools using AC current supply will fulfil one of the following
requirements:
a. Voltage 50V to 110V single phase – must be fed from a dual winding transformer with
midpoint of secondary earthed.
b. Voltage 230V and above single phase – must be of the approved type with double
insulated construction.
(17) Do not use test lamps or other electrically operated instruments unless they are of an
approved type. Makeshift testers and long bare metal prods are dangerous to gas plant
operation.
(18) All electrical tools must be switched off and made inoperative before moving the
connecting plug.
(19) When work is performed on electrically powered equipment and associated circuits, the
Electrical Tag Out (ETO) Permit will be applied prior to work commencement. The ETO
Permit will not apply to:
a. Lighting circuit for the purpose of re lamping.
b. Window or package air-conditioning units and outgoing circuits from distribution
panel for lighting and socket outlets.
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Method Statement
c. Circuits of less than 230V and circuits which must remained energized. In such
cases, the method of work must be established and the Electrical/ Safety Section
duly notified.
3) Welding Machines
(1) All AC supplied welding machines will be fitted with Low Voltage Shock Presenters and
will be tested every day before work commencement.
(2) All subcontractors will attach a tag on the welding machine their company names and the
name of the person responsible.
(3) All welding cable will be of proper insulation having a dielectric strength of not less than
the rated voltage of 600V.
(4) All welding machines will be provided with proper earth cable connected with brass or
steel bolts and nuts.
4) Explosive Powered Tools

(1) A permit is required for the use of explosive power tools, whether operated by cartridge,
air, or electric.
(2) All explosive powered tools shall be permanently embossed, printed, or placed with the
following warning:
“DO NOT REMOVE THIS TOOL FROM THE WORK SURFACE FOR ATLEAST
10SECONDS AFTER IT HAS FAILED TO FIRE”
(3) Serial number and model identification of the tool shall be permanently engraved or
embossed on the exclusive power tools
(4) A register shall be kept, updated and maintained regularly for all explosive powered tools.
(5) All explosive powered tools shall meet local government requirements.
(6) Only competent operator who has completed a course of training on the operation of a
direct acting explosive powered tool can operate a direct acting tool.
(7) No person shall leave a tool-unattended unless effective precautions has been taken to
ensure that it will not be removed, handled or used by any person other than the person
using or assisting in the use of the tool.
(8) Authorized person using the tools shall read the instruction manual thoroughly and
understand the operation procedure and danger connected with their use.
(9) The operator shall check his tool each time before use and any fault or malfunction
detected shall be reported immediately.
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Method Statement
(10) Do not use them on hard brittle material or into steel of greater hardness than the
fastener being used.
(11) All personnel must be cleared to do the area behind and on indirect line of the possible
flight line of fixing. Consideration must also be given to the possibility of ricochet.
(12) The operator shall use ear protector when the tool is used in confined space.
5) Portable Hand Tools
(1) Special attention shall be paid to hand tools that can cause sparks when struck on
concrete or metal. The sparks can ignite flammable gases and cause fire and explosion.
Use non-sparking tools in hazardous areas or on vessels containing flammable gases. If
this is not practical do not start work, consult your immediate supervisor.
Note: Tools made of beryllium bronze can also produce sparks on frictional impact with
aluminium-painted iron or steel surface.
(2) Always use the right tools for the right job.
(3) Ensure all portable tool shall be defects free and before the first use check that they are in
good working conditions, it in doubt refer to your immediate supervisor or Tool Store for
advice.
(4) Tools must not be thrown to another person.
(5) Use proper tool bag to carry tools that are required for work at height in order to prevent
them from dropping off.
6.5. Excavation Work
1) Permit to Work
(1) Excavation work shall be defined as any digging work on the ground (earth or concrete)
either by manual or mechanical means and shall require an Excavation Permit. The work
shall include miscellaneous work, such as tree planting, installation of road signs or flag
posts, etc., and piling work which may affect the adjacent plants or underground facilities.
2) Hazards Identification
Special attention shall be paid to those trenches being dug within process plant area or any
place where there are possible sources of flammable or toxic gas emission. Such emission
sources may be from the nearby equipment or the pipes underneath the trenches. Therefore
any trench that exceeds 1.5m in depth may require atmosphere testing before any person is
allowed to enter.
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Method Statement
3) Safety Rules And Regulations

(1) Where a trench to be excavated exceeds 1.5m in depth, adequate piling, shoring and
bracing shall be provided against the bank or side to prevent it from collapsing.
(2) The materials used for piling, shoring and bracing shall be of adequate strength.
(3) Where trenching of more than 3m in depth is done, barricades made of rigid material shall
be used. Covering the trenches with canvass sheet or the like without such barricades is
strictly prohibited.
(4) Safe means of access and egress such as ladders, stairways or ramps shall be provided
for trenches with 1.2m in depth or more.
(5) All road crossing trenches shall be covered by steel plates of sufficient strength for
vehicle to pass over.
6.6. Crane Lifting Operation
Considering the need for the use of crane in the lifting operation of heavy loads – construction
materials and equipment, cranes will be hired from a reputable local source. Equipment
suppliers and operators will required to provide the necessary documents and certificates
including equipment certification, equipment maintenance record, operator’s license, rigger
certificates, checklist on lifting shackles, straps, slings, and others, that may be used during the
lifting operation.
A Cranage Coordinator shall be appointed to conduct monitoring on the setup and to supervise
lifting operation, so as avoid lifting of unsafe loads. He will ensure that the lifting equipment or
crane is suitable for the purpose and also to notify the schedule of lifting operation to others in
the area of operation.
6.7. Piling for Excavation Protection Work
Prior to the commencement of any piling works, the stability of the adjacent structure shall be
surveyed and determined. The piling equipment shall be thoroughly examined by an approved
person once in every 6 months.
1) Procedure
All pile driving equipment before coming to the work site shall be thoroughly examined by an
approved person.
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Method Statement
2) Preparation
(1) All works involving the use of pile driving equipment shall be properly planed, organized
and coordinated to ensure that all necessary safety precautions are taken.
(2) Check and confirm with the Engineer to ensure that the area for piling is free from
underground cables, pipes or structures.
(3) Ensure all preparation work for the piles is conducted at a safe distance from the driving
operation.
(4) During the hoisting of the pile all persons not actually engaged in operating the
equipment and handling the piles shall be kept out of the area.
(5) Every day before work commencement the piling equipment shall be inspected, and any
defects found shall be rectified.
(6) Provision shall be made to protect the operator from falling objects, steam, cinders and
water.
(7) When the pile driver is not in use the hammer shall be choked or blocked in the leads or
lowered to the ground.
(8) A ladder extending from the bottom of the leads to the overhead sheaves shall be
permanently attached to the structure supporting to the leads.
(9) Where a structure supports the leads, a suitable working platform of adequate strength
shall be provided on the level of the leads at which it is necessary for men to work.
(10) The working platform shall be provided with safety railings and the boards on all sides,
except on the hammer, or lead side of the platform.
(11) Where such platform cannot be provided, full body harness or safety belts shall be used.
(12) Before placing or advancing a pile driver, the ground shall be inspected and where
necessary for firm or level footing, timber shall be placed. After placing or advancing a
pile driver, inspection and correction of the footing if necessary shall be made to maintain
stability.
3) Operation
(1) The Supervisor-in-charge shall prior to work commencement provide clear instructions to
the operator regarding safe work operation.
(2) The operator shall be provided with the necessary personal protective equipment such as
safety helmet, safety shoes, ear protectors, etc. to protect him from personal injury and
health damage.
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Method Statement
(3) Piling work shall be executed in accordance to drawings provided by Contractor or by

Engineer.
(4) Piling .work shall be conducted by experienced staff capable of dealing with all pile
pitching and driving, and if necessary, the extraction of the pile.
(5) Pile shall only be installed in the presence of the Engineer or his authorized
representatives.
6.8. Rock Breaking/Excavation
Whenever necessary, rock breaking/excavation will be done using heavy earthmoving

equipment and latest technologies on hard rock breaking/excavation without blasting. This rock
breaking/excavation methodology will employ applicable procedures, as for:
1) Rock breaking using rock splitting method by Hydraulic Rock Splitters;

2) Rock sawing using Diamond Wire Saw Equipment;
3) Rock cracking using Chemical Expansion Mortar to crack the rock, and breaking it using
Hydraulic Rock Breakers;
4) Rock breaking using Excavator mounted with Heavy Hydraulic Rock Breakers;
5) Rock breaking by Compressors with Pneumatic Jackhammers; and
6) Rock breaking using manual chiseling and wedging method.
7. Safety Plan
Please see Attachment 7: Technical Proposal - HSE Plan in this Bid Proposal
8. Environmental Management Plan
Please see Attachment 7: Technical Proposal – HSE Plan in this Bid Proposal
9. Division of Works
The Construction and Installation Works will be broken down into the following categories:
38 / 149
Method Statement
9.1. Mechanical and Electrical Portion
1) Installation of Equipment and Machineries

(1) Submersible Pumps
(2) Fine Screens
(3) Air Blower, Compressor
(4) Secondary Clarifier Equipment
(5) Belt Filter Press
(6) Chlorination System
(7) Bio Filter Odor Control System
(8) Diesel Engine Driven Generator
(9) Others
2) Piping Installation
(1) Force Main (DI Pipe)
(2) General Piping (Stainless Steel, PVC, etc.)
3) Electrical Work
(1) Power Distribution
(2) Low Tension Power Distribution System
(3) Lighting
(4) Street Lighting
(5) Generator
7) Instrument Installation Work

a. Flow Meter
b. ORP DO Meter
c. Level Switch
d. SCADA
e. Others
8) Painting
a. Steel Structures
b. Supports and Framings
c. Others
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Method Statement
9) Commissioning and Test Run

a. Pre-commissioning
b. Commissioning/Guarantee Test
9.2. Pipeline Works
1) Pipe Laying Works

(1) Force Main Influent Line Piping
(2) Gravity Effluent Line Piping
(3) Other Yard Piping
2) Manholes Construction
9.3. Civil and Building Portion
1) Mobilization
2) Construction Camp Yard
3) Temporary Road
4) Temporary Workshop and Warehouse
5) Transportation Materials
6) Design (Mechanical and Electrical Plant Structures)
7) Site Office
8) Reclamation
9) Soil Improvement
10) WWTP Area
(1) Flow Meter
(2) Grit Chamber
(3) Oxidation Ditch
(4) Sedimentation Tank
(5) Disinfection Building
(6) Sludge Pumping Station
(7) Sludge Treatment Building
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Method Statement
11) Building
(1) Administration Building/Control Room
(2) Liquid Process Control Building
(3) Blower Room
(4) Generator Room
(5) Guard Post
12) Site Development Works
(1) Landscaping
(2) Pavement
(3) Fence and Noise Barrier
(4) Storm Drainage System
(5) Plant Utilities
9.4. Operation & Maintenance
1) Operation
2) Preventive Maintenance
3) Analysis
4) Monthly Report
10. Work Methodology
10.1. Mechanical and Electrical Works
Method of working for major items of Mechanical & Electrical Portion in this project will be
generally as follows:
10.1.1. Equipment Installation
1) General
(1) Scope
This specification covers the requirements for the installation of equipment that will be
used in the plant.
(2) Codes
The applicable codes and standards shall be indicated in Specific Job Requirements.
41 / 149
Method Statement
(3) Units
Unless otherwise specified, metric units shall be used as the measurement system for the
drawings and documents to be submitted.
2) Safety and Sanitation

Full care and precaution shall be given by the field management for the safety of the workers
in the field to prevent accidents during the execution of the works.
3) General Requirements
(1) Work Execution
All works shall be implemented carefully and without delay.When required, the works
shall be supervised and performed by qualified personnel or technicians as
recommended by the manufacturer.
(2) Precautions for Installation
When the equipment is lifted by using ropes, protection pads shall be placed in between
the rope and equipment body to prevent dents and scratches.
The operator of the winch or crane shall be careful and always be attentive, when lifting
or unloading the equipment. Construction equipment, machines, tools and measuring
instruments to be used in the works shall be checked thoroughly before using.
When sling is used in lifting or lowering the equipment, the center of gravity shall be
properly considered in order to avoid damage on the equipment. Lifting hooks when
available shall be used.
If winch is used for loading or transferring of equipment, the path of the equipment should
be properly cleared to avoid injuries to the workers.
4) Unloading and Transportation

(1) Unloading
For heavy equipment, unloading method shall be determined by investigating the
following items, and unloading plan shall be made out prior to the works.
a. Size, weight and shape of the equipment
b. Unloading facilities on the pier.
c. Accessible distance to the pier of the transport vessels
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Method Statement
d. Conditions of the ground at the unloading point.

e. Means of communication with transport vessel.
The ground at the unloading point, if it is not firm, shall be thoroughly reinforced in order
to prevent the equipment from overturning, etc.
Prior to unloading, the orientation and position of the equipment after unloading shall be
confirmed in relation to the direction of installation.
(2) Transportation
For transportation of the heavy equipment after unloading, transportation method shall be
determined by investigating the following items and transportation plan shall be made out
prior to the works.
a.) Size, weight and shape of the equipment.
b.) Maximum allowable loads for the roads and bridges in the transport routes.
c.) Width and conditions of the road on the transport route.
d.) Building, aerial wirings, overhead girders, electric posts, underground facilities in the
transport route.
If so required, whether or not a temporary road is necessary proper reinforcements,

obstruction removal or protection shall be done to the roads. Underground facilities and
buried objects or existing structures around the transportation route shall also be checked
to prevent them from being damaged. Measures shall be promptly implemented to
restore it to original conditions after the works have been completed.
Where highway is passed over, detailed investigations shall be made regarding the
restrictions of time, size, weight, traffic, etc.
In the field, the equipment shall be temporarily placed at the points shown in the
transportation plan. Skids for transporting and temporary placement of equipment shall
be made properly equipment to avoid damages.
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Method Statement
5) Custody of Equipment
(1) Unpacking
Upon arrival of the equipment in the field, the number and external appearance of the
package shall be checked based on the packing list.
After unpacking, the specification of the equipment such as dimensions, weight and
quantity shall be checked based on the packing list, purchase order and / or invoice.
Anything that is defective such as appearance of rust, defect or distortion shall be
checked.
Centering marks, orientation marks, markings of center of gravity and sling point shall be
checked according to the drawings.
(2) Safekeeping
The place and method of safekeeping until installation shall be determined taking the
following items into consideration:
a.) Type of the equipment, parts, accessories and spare parts, if any.
b.) Property of material used and finished surface.
c.) Period of stocking and weather condition.
d.) Environmental condition, such as whether or dust, sand or soil, corrosive gas, etc.
exists.
Cleaning and application of anti-corrosive treatment or sealing, if necessary, shall be

made.
6) Lifting Method
(1) General
The following shall be considered for the selection of the lifting method and the erection of
lifting equipment.
a.) Size, weight and shape of the equipment to be installed, and the slinging points.
b.) Space of the location of installation.
c.) Space and ground condition at the place of erecting the lifting equipment.
d.) Buildings, structures, equipment, etc. existing nearby and whether or not those can
be utilized.
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Method Statement
e.) Buried objects such as underground piping and cables and open trenches existing at
the place where lifting equipment is erected.
f.) Condition of roads as to whether it can be used or not.
g.) Space for dismantling or taking out the lifting equipment.
For heavy weight equipment, installation procedures including specification of the lifting
equipment, routing and method for hauling of the equipment from the temporary location,
the direction and sequence of installation, etc. shall be made, before starting the works.
In general, the chocker hitch sling shall not be used for heavy weight equipment. If use of
such sling is inevitable, strength of the equipment shall be determined and
countermeasures against slipping off, impact, etc. shall be made prior to lifting works.
(2) Installation with Gin Poles

In addition to the installation manual specified in Paragraph 6.1.2, the arrangement and
dimension of dead man shall be determined and the strength calculation sheets for the
gin poles to be used shall be made, prior to the erection of the gin poles.
The following design criteria shall be used for the strength calculations:
a.) Coefficient of dynamic load : 1.25
b.) Stay wire bracing angle : 30 degrees or less
45 degrees maximum,
if unavoidable
c.) Safety factor of the dead man : on load, 6 or more

on no-load, 4 or more
d.) Safety factor of the dead man : 2.5 or more
e.) Wind Velocity : on load, 16 m/sec

on no-load, 50 m/sec
f.) Seismic Coefficient : 0.2
g.) Efficiency of Pulleys : 0.95 per one pulley
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Method Statement
h.) Friction Coefficient of the Ground : 0.3
i.) Specific Gravity : 2.3 ton/ m3
j.) Specific Gravity & Internal Angle of Soil : to be investigated
k.) Coefficient of Wind Pressure :
For Gin Poles : 1.6

For Cylindrical Equipment : 0.7
Erection of the gin poles shall be as follows:
a.) Dead man shall be duly installed at proper positions based on the installation manual.
b.) Assembly of the gin poles shall be done on flat ground and any misalignment of bolt
holes shall be completely corrected.
c.) Bolts at joints shall not be over tightened.
d.) Erection of the gin poles shall be carried out by the use of truck crane or auxiliary gin
poles.
e.) Equalizer beam shall be mounted after the gin poles have been erected and the stay
wires firmly braced.
f.) Bracing of the stay wires shall be checked again after the equalizer beam has been
mounted.
g.) Markings shall be made at fastening wire clip of the stay wire tail end for checking
any slip of the stay wire after adjustment.
h.) Winches (for lifting, drawing-in, etc.) shall be set at the locations specified in the
installation manual, and tied with dead man using wire ropes. Slipping off or upward
moving of the winches shall be avoided by all means.
(3) Installation with Truck Crane

The rated load and operating radius of the truck crane shall conform to the figures
specified by the crane manufacturer.
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Method Statement
Outriggers shall be fully extended and thus the crane shall be firmly fixed. The ground at
which the outriggers are set should be reinforced in order to prevent the crane from
overturning, etc.
Lifting angles (the angle between the sling wire and perpendicular axis at the hook of the
crane) shall generally be less than 30 degrees or if unavoidable case, 45 degrees
maximum.
(4) Installation with Other Method

Where special lifting equipment such as tower crane is used, Specific Job Requirements
shall be complied with.
Where the equipment is installed under pipe rack or in the building where the truck crane
cannot be used, the equipment shall generally be rolled into its point of installation and
shall be installed with chain block, etc.
10) Preparation for Installation

(1) Measuring Instrument and Tools
Required quantity of measuring instruments and tools to be used for installation shall be
prepared.
(2) Foundation
Equipment foundation shall be checked for the following items:
a. Period of curing for foundation concrete
b. Dimension
c. Position (centerline marking) and height (level marking)
d. Absence of disorders in the foundation concrete, such as abnormal concentration of
aggregates and other defects.
e. Size of anchor bolts and damage or rust of threaded parts
f. Dimension and cleanliness of anchor boxes, if anchor box is applied.
(3) Treatment of the surface of the foundation, such as chipping and fitting, shall be carried
out as follows:
a.) Remove foreign matters completely.
b.) Chip the portions which come in contact with liners and fit them in line with liners.
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Method Statement
c.) If grouting is made after centering, chip the surface so as to give good adherence and
avoid cracking, peeling-off, etc. of grouting mortar.
(4) Liners
Liners to be used shall be, in general, made of carbon. In case of corrosive environment,
liners made of non-corrosive material shall be used.
Liners shall be so arranged that the load of the equipment is uniformly and exactly
distributed to the foundation within allowable load. The liners shall be placed as near as
possible to both sides of each anchor bolts.
In case where only flat liners are used for alignment, these flat liners shall be piled in 3
layers or less.
In case where wedge liners are used for alignment, gradient of the wedge liners shall be
1/30 – 1/60, and two wedge liners shall be put together in back to back manner so as to
have their top and bottom faces in parallel. And as base liner, flat liners having about 2
times the thickness of the wedge liners, shall be put under the wedge liners.
Dimension, gradient and surface roughness of liners shall be as shown in the attached
Table 2, Standards of Liners.
(5) Equipment
Prior to the installation, the following checking for the equipment shall be made:
a.) Appearance of equipment, such as absence of damage and rust.
b.) The quantity and appearance of auxiliaries.
c.) Size of the anchor bolts, and absence of damage and rust on the threaded parts, if
anchor box is applied.
d.) Orientation marking.
e.) Marking of the center of gravity.
f.) Sling points.
Oil and other foreign matters stuck on the surface of legs, bed, frame, etc., which will
contact the grouting mortar shall be entirely removed.
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Method Statement
11) Installation
(1) Setting
Setting of the equipment on the foundation shall be, as a rule, performed as shown in the
attached Table 1 - Standards of Setting.
Placing of the equipment shall be carried out as follows:

a.) Liners shall be set so that the top levels of these liners come slightly lower than the
installation height thus allowing later adjustment.
b.) Equipment shall be put down slowly with chain blocks, jacks, etc., keeping it
horizontally.
c.) In case of anchor box type, the anchor bolts shall be set to the legs of the equipment
after stabilization of the lowered equipment has been obtained.
d.) All anchor bolts shall be tightened completely and uniformly.
Centering or alignment shall conform to Engineering Specification corresponding to each

equipment installation work.
Where the liners are used in multi-layers, they shall be intermittently welded to each other
after completion of centering or alignment.
In case of anchor box type, fixing of the anchor bolts shall be carried out as follows:
a.) Anchor bolts shall be set so that a few screw threads come out from the nut.
b.) When mortar is being poured into the anchor boxes, thoroughly check if it’s free from
foreign matters before the mortar shall be poured. Cover the threaded part of the
bolts to prevent splashes of mortar getting stuck.
c.) Mixing ratio of the mortar shall be specified in attached Table 3. Standard in Mixing
Ratio of Mortar.
d.) All anchor bolts shall be tightened completely and uniformly after sufficient curing of
the mortar has been attained.
(2) Grouting
Grouting of the base of the equipment shall be carried out as follows:
a.) The grouting shall be done by damping the surface after cleaning.
b.) When the grouting mortar is being poured into the gap between the bed of the
equipment and the foundation, it shall be done continuously and should be
monolithic.
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Method Statement
12) Inspection
Inspection required in the works shall conform to the Engineering Specification corresponding
to individual equipment installation works.
10.1.2. General Plant Piping work
1) General Notes
(1) Scope
This specification covers the requirements for fabrication, assembly, erection, inspection and
testing and other field works of all piping.
(2) General Remarks

Process and utility piping shall be fabricated in accordance with codes, drawings, and the
requirements specified herein.
When conflicts exist between the aforementioned documents, this specification shall govern
except when code requirements will apply.
(3) Codes
Unless otherwise specified, the fabrication of piping shall be in accordance with the Code for
Chemical Plant and Petroleum Refinery Piping, ANSI B31.3, latest edition.
(4) Reference Documents
On piping works, the following latest documents shall be referred to as a part of this
specification:
Title Doc. No.

__________________________________________________________
a. Isometric Drawings __
b. Piping Arrangement Drawings __
c. Fabrication Drawings for Pipe Supports __
d. Pipe Sleeve Drawings __
e. Specification of Welding of Steel Piping __
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Method Statement
2) Materials
i. Material Identification
Pre-fabricated piping sections shall be marked with their specific spool number.Piping
materials to be used are indicated on the material list on the applicable isometric
drawings by Code Number or Tag Number.
Prior to the fabrication, identity of the materials shall be confirmed by an identification

mark which has been applied on the material surfaces, such as Code Number or Tag
Number.
ii. Material Storage

Light materials which can be manually handled shall be stored in warehouses.
Heavy materials may be stored outside in proper arrangement so that they can be easily
taken out with a suitable lifting device.
However, the following protections shall be taken into consideration:

a.) Materials shall be covered with a waterproof sheet to protect it from rain and dust.
b.) Materials shall be placed on a paved floor or elevated floor above finish grade.
c.) Valves shall be stored under the following conditions:
c.1) Disc : Fully closed position
c.2) Stem : Vertical Position
c.3) Opening : With protection covers
Irrespective of the weight and/ or volume, the following materials shall be stored indoors:
a.) Check, Ball, Butterfly and Special Valves with actuator.
b.) Sight glasses, expansion joints, flexible tubes and other piping accessories.
c.) Chemicals and consumables
d.) Spare parts
Welding Electrodes - Electrodes shall be stored indoors and dried as needed.
All materials shall be stored with proper identification based on types (color codes),
sizes and Tag No., in order to facilitate issuance and inventory of materials.
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Method Statement
iii. Material Control

Good material management is one of the most important factors to make a successful
control of all piping works, and avoid incorrect usage and lost materials which may result
in the delay of construction schedule.
All materials under storage shall be controlled by well-trained warehouse keepers.
When materials are delivered, warehouse keepers shall properly record material
balance in such a way that;
a.) When stored, quantities are kept on record with reference to a packing list.
b.) When being delivered, quantities are registered by reference to Code No. or Tab
No. indicated on a material list of applicable reference drawings.
3) Fabrication
(1) General
Threaded Connections - Threads shall conform to JIS B0203: PT or ISO 7/1 Tapered
Pipe Threads, unless otherwise specified.
Socket Welding -Care shall be taken to ensure that a clearance of approximately 1.6
mm remains between the male and female ends at the bottom of the socket.
Longitudinal seams in adjoining lengths of welded pipe shall be staggered and located
so as to provide openings between external attachments and weld lines as shown in the
figure below.
Figure 1: Location of Longitudinal Seams
L3
Lo
L2
Min Lo = four (4) times the nominal wall thickness or 25 mm, w/e is greater
Min L1 = five (5) times the nominal wall thickness
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Method Statement
Min L2 = three (3) times the nominal wall thickness

Min L3 = three (3) times the nominal wall thickness or 25 mm, w/e is greater
When pipe works are prefabricated, the contractor shall reflect the adjustments points
on the Isometric Drawings according to actual field conditions.
Prior to fabrication work, shop–applied rust preventive coating shall be removed from all
piping material surfaces by solvent cleaning.
(2) Cutting and Bevelling

Pipes and fittings shall be cut preferably with cutting machine or gas cutting and beveled
by machining or grinding.
Gas cutting, arc cutting for stainless steel shall be used for rough cutting only. In this
case, the cut part shall be made smooth by grinding. But these procedures are not
necessary for carbon steel and low alloy steel.
Cutter blade of abrasive cutting machine for cutting austenitic stainless steels shall not
be confused with that used for cutting carbon steel.
Plasma jet cutting may be applied for stainless steel, etc.
End preparation for welds shall be done by mechanical means when practicable or
grinding. Flame-cut surfaces shall be ground properly.
(3) Welding
All welding works shall conform to the requirements described in the following
specification:“Specification for Welding of Steel Piping “
Approval of the welding procedures to be used and of the performance of welders will be
required and shall comply with the requirements of Section IX of the ASME Code.
A performance qualification for welder under country laws or regulations shall be

acceptable, if the qualification covers applicable scope of welding (e.g., welding process,
material, and welding position).
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Method Statement
Welding processes shall be determined by the welding abilities of the welders, within the
limitations described in Welding Specification.
However, the welding processes for butt circular welding are required. Insert rings and
backing rings shall not be acceptable.
Tack welds shall be done by a qualified welder and procedure based on the final welding.
Electrodes used for tack welds in the root pass shall be of the same type as that one
being used for the first pass.
All welds on pressure containing parts shall be accomplished with a qualified procedure
and by qualified welders. If seal welds for threaded joints are required, all exposed
threads shall be covered by the seal weld and must be done by qualified welders.
Welding on pipe supports shall be made by qualified welders.
(4) Bending
When welded pipe is bent, the longitudinal weld shall be located between 10” and 15”
away from the neutral axis.As a rule, the bending radius shall not be less than 5 times
the nominal pipe diameter.
Bends in carbon steel piping may be made in hot or cold condition by any procedure
which will not cause wrinkling, excessive thinning or scaling of the pipe wall or flattening.
Bends in austenitic stainless steel piping must be made in cold condition by a procedure
which will not cause wrinkling, excessive thinning or scaling of the pipe wall or flattening.
If the above condition is not feasible, the bends may be made by high-frequency
induction heating. The maximum decrease of wall thickness shall not exceed 10% of the
maximum wall thickness. This minimum wall thickness is 87.5% of the nominal wall
thickness.
The maximum flattening, as measured by the difference between the maximum and
minimum diameter at any cross section, shall not exceed 8% and 3% of the nominal
outside diameter for internal and external pressure respectively.
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Method Statement
(5) Branch Connection

All cuts shall be carefully beveled and accurately matched to form a suitable groove for
welding and to permit complete penetration of the welds at all points.
Welded pipe to pipe branch connections shall be directly joined to the run pipe with full
penetration welds.
The reinforcing pad, if required, shall be provided with a 1/8” in. PT hole telltale hole.
(6) Flanged Joint

Unless otherwise noted on the fabrication drawing, the bolt holes of flanges shall be
properly positioned on the center lines of the pipe ends.
Orifice runs shall not contain welds except at the flanges. Pipe ends and bevels at orifice
flanges shall be machine cut and shall be perpendicular to the axis of the pipe. Welds at
orifice flanges shall be ground smooth and flushed inside. Pipe tap connections on slip
on orifice flanges and directly on the pipe, if specified, shall be drilled through the pipe
wall. And it shall be finished smooth and flushed and cleaned inside.
Taps shall be oriented as shown on the isometric drawings.
(7) Heat Treatment

Preheat and Inter-pass temperature (P & IPT)
a.) P and IPT shall be in accordance with Table 3, unless otherwise specified.
b.) P and IPT shall be in be checked by using temperature indicating crayons,
thermocouple pyrometers or equally suitable means.Temperature indicating
crayons shall not cause corrosive effects or other harmful effects on austenitic
stainless steel.
c.) Heating width at preheating shall be three times the pipe thickness to each side from
the bevel ends. But it is not necessary to exceed 100 mm.
d.) Preheating shall be performed by propane or oxyacetylene flame prior to
commencing the weld.
e.) P and IPT requirements listed above shall also apply to tack welding and the
welding of temporary attachments. Preheat requirements above shall also apply to
all thermal gouging and cutting.
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Method Statement
(8) Surface and Weld Defects

Unless otherwise specified, surface defects shall be considered critical if the defect
extend below the specified minimum wall thickness or is more 2 mm (1/16”) deep.
Surface defects shall be completely removed by grinding. The ground out area shall be
repaired by welding if the defect removal results in reduction of pipe wall thickness
below minimum. The repaired area shall be ground smoothly.
(9) Dimensional Tolerance

Tolerance for finished fabricated piping shall conform to Figure 2 and Figure 3.
(10) Cleaning
All fabricated piping assemblies shall be cleaned by air or water to remove scales and oil
on the inner surface and shall be dried out with air blow.
If water is used in cleaning stainless steel piping assemblies, it shall not contain more
than 50 ppm of chloride.
(11) Inspection and Test

Inspection and test shall be performed in accordance with Section 5 of this specification.
4) Assembly and Erection

(1) Cleaning Prior to Installation
Prior to installation of prefabricated piping and other piping components, the sections
shall be thoroughly cleaned both on the interior and exterior surfaces to remove sand
and other foreign materials. Cleaning shall be made by air blowing.
(2) Assembly of Prefabricated Piping

Prior to the installation of prefabricated piping, actual dimensions necessary for final
piping system shall be based on actual field adjustment points. When the prefabricated
piping of adjusted dimension are fitted up, distortion shall be avoided when
misalignment are corrected. Distortion will introduce excessive forces and moments.
The misalignment shall be limited as listed in Figure 4, unless otherwise specified.
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Method Statement
When flanged joints are assembled, the gaskets and flanges shall be bolted with
relatively uniform bolt stress consistent with the type of gasket used. Connection of steel
and cast iron flanges shall be bolted with care so as not to damage the cast iron flange.
Threads of bolting shall be coated with a suitable compound before installation to
prevent damage on the threads.
Gasket paste shall not be applied to the gasket unless otherwise specified.
(3) Threaded Joint

Threads shall conform to JIS B0203: PT which is equivalent with ISO 7/1.
Standard length of threads:
l
f a - normal engagement by hand
a f - usable threads length
l - effective threads length
TABLE 2: LENGTH OF ENGAGEMENT

UNIT: mm
NSP (B) 1/4” 3/8” 1/2” 3/4” 1” 1 1/2” 2” 3”
4”
a 6.01 6.35 8.16 9.53 10.39 12.7 15.88 20.64 25.4
f 3.7 3.7 5.0 5.0 6.4 6.4 7.5 9.2 10.4
l 9.7 10.1 13.2 14.5 16.8 19.1 23.4 29.8 35.8
Checking of Threads - Check the threads for pipe fittings based on the following
procedures:
a.) Checking of external threads
a.1) When stain or foreign materials stick on the threads, clean with steel brush
along the screw threads.
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Method Statement
a.2) Check that insertion can be done smoothly by inserting the ring gauge or the
opposite fitting.
a.3) Check that the length of complete threads portion is not less than the value
as indicated in Table 2.
b.) Checking of internal threads.

b.1) When stain or foreign substance sticks to threads, clean with a steel brush
along the screw threads.
b.2) Check if tightening can be done smoothly by inserting the plug gauge or the
joint to be fitted.
c.) Checking length of engagement.

c.1) By using the fitting to be connected. Insert the fitting by turning it manually
until it stops. Check that the length of engagement is not less than the value
indicated in Table 2.
c.2) By using thread gauge. Insert the ring gauge into the external threads and
the plug gauge into the internal threads.
.Sealing Materials for Threads - In principle, TFE Seal Tape shall be used for
all threads except where seal welding is applied.
iv. Assembly of Piping Sections

When piping sections are assembled by welding, fabrication shall be done in
accordance with the requirements described in Sections 3 and 4.2.
When piping accessories are installed with flanges in piping system, such as valves,
strainers or expansion joints, the requirements specified in Section 4.2 for flanged
joints shall be equally observed.
1.) Valves
a.) Valves shall be installed in piping system on closed position.
b.) Globe, check and control valves shall be installed considering the fluid flow mark.
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Method Statement
2.) Instruments
a.) Instruments mounted in-line may be installed to establish the actual dimensions of
final piping systems.
However, the instruments shall be removed during cleaning of the internal part of
the piping system
b.) All restrictions such as orifice plates or flow nozzles shall not be installed until the
completion of pressure tests and line cleaning operations.
3.) Supports
Pipe supports shall be installed prior to assembly and erection of piping system. This
will be necessary for piping alignment.
Temporary supports, if needed, may be used.
v. Requirements for Piping Connected to Rotating Machinery

This requirement shall be applied to piping of 3 inches nominal diameter and over.
Alignment Procedure - After completion of machine driving shaft preliminary alignment,

the following procedures shall be performed:
i. Complete the installation of all piping connected to the equipment.
b.) Unbolt each flanged joint that is adjacent to the equipment.
c.)Visually check the unbolted joints to ensure that the flanges are in proper alignment.
d.) If required, while the joints are reconnected, this alignment shall be inspected to
ensure that excessive strain to the equipment is avoided.
e.) Improper alignment shall be corrected and the joints shall be rechecked.
Alignment of the flange connected to the equipment shall be within the limits listed in
Figure 4.
Records of pipe flange misalignment (with the piping free and unrestrained), and
showing the effect of the piping connections on the machinery shaft alignment shall be
prepared and ready for request of representative.
Equipment Protection - Whenever work is done on piping connected to rotating

machines, precautions shall be observed and protections shall be provided to prevent
any welding spatter, metal chips, or other debris that will damage the equipment.
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Method Statement
vi. Miscellaneous
Unless otherwise specified, all equipment, piping and valves which are of a temporary
nature shall be designed and prepared by the contractor in a safe and sound manner.
These shall include such lines as temporary vents for air blowing, piping required for
pressure tests and all other piping that are required for the successful completion of
the permanent piping systems.
The temporary piping shall be removed before starting the final leak test.
Assembly and erection work of piping shall carefully be performed without any
damage to equipment, piping and instruments which have been installed.
All joints including welded joints shall be left unpainted and uninsulated until
completion of field pressure testing.
Piping on Pipe Rack - For piping run on pipe rack, precaution shall be observed so
that the field weld point will not coincide with rack beam.
Piping Connected to Vessels - The large-sized piping that is connected to a vessel at

high elevation such as overhead piping from column shall be prefabricated as much
as possible and the pressure tests shall be conducted on the ground before
installation.
5) Examination and Inspection

(1) General
Prior to initial operation, examination and inspection shall be conducted to ensure
that the piping works are in compliance with the design, material, fabrication,
assembly and erection requirements of this specification and of other reference
documents.
(2) Inspection of Materials

The materials used in fabrication and erection shall be inspected in accordance with
Section 2.1.
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Method Statement
When any doubt exists as to the quality of materials, the materials shall be assured
by verification of certifications, records or other evidence that they are of the specified
grades and ratings, and that they have received required heat treatment, examination
and testing.
(3) Inspection of Welds

Unless specified in the applicable Welding Specification of Par. 3.3.1 and this
specification, inspection of welds shall be subject to the ANSI B31.3 - Chemical Plant
and Petroleum Refinery Piping.
Fit up Inspection
Before welding, all welding joint parts shall be checked on the following items.
a.) Bevelled part shall be fully cleaned so that there is no rust, oil, paint, and
moisture.
b.) End Penetration
End penetration for butt-welding shall be in accordance with “Specification for
Welding of Steel Piping.
c.) Misalignment
Misalignment at butt-welding shall in accordance with “Specification for Welding
of Steel Piping”
(4) Dimensional Check

Before shipment from shop and during erection, all parts and dimensions for each
piece of piping shall be checked to assure that the finished pieces meet the
requirements of the reference drawings and this specification. The tolerance for
fabricated piping shall conform to Figure 2, 3 and 4.
(5) Cleanliness
In order to prevent the damage to machine and aid in the trouble-free start of the
units, cleanliness of all piping should be inspected by the following stage:
a.) Before transport from the shop, cleanliness for prefabricated piping is inspected
in accordance with Par. 3.10.
b.) When prefabricated piping are assembled and erected, cleanliness for
prefabricated piping is inspected in accordance with Par. 4.1.
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Method Statement
c.) After completion of pressure testing and when flushing the piping systems,
system cleaning is performed in accordance with Clause 7 and the cleanliness
is evaluated by dirt being included in the fluid which is discharged from ends of
piping systems, or by dirt being left behind on the temporary strainers which are
inserted into the piping system, in accordance with Clause 7.
d.) After water circulation operation, the final cleanliness is checked by dirt being
left in the strainers.
(6) Line Check

Before pressure testing, all parts of final erected piping systems shall be checked to
assure that they meet the requirements of isometric drawings and other reference
drawings.
The inspection shall be established by checking the following points:

a.) Starting and ending points of pipe lines
b.) Branching points
c.) Tag No. and Code No. of piping accessories furnished in pipe lines.
d.) Tag No. of instruments mounted in pipelines
e.) Orientation for handles or spindles of the equipped items.
f.) Orientation for the items having a specific flow direction.
g.) Fixed and guided points on pipe supports
h.) Other items shall be checked during dimensional check.
6) Pressure Tests
(1) General
Test fluid and pressure shall be applied to each piping systems as specified in Pipe
Line Schedule, or other reference drawings.
Unless otherwise specified herein, the requirements specified in ANSI B31.3 Par. 337
shall govern.
(2) Test Fluid

When water is used for austenitic stainless steel piping, the chlorides content shall not
exceed 25 ppm.
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Method Statement
7) Cleaning
(1) Standard Cleaning of Piping System
After completion of pressure testing, all piping systems shall be flushed until they are
thoroughly cleaned of loosed scale, debris and other foreign materials by suitable
means using air or water.
8) Final Leak Tests

(1) General
Prior to initial operation, all parts which are unbolted at the time of pressure testing,
cleaning and water circulating operation shall be retested pneumatically.
Prior to final leak test, the following points shall be carefully checked for all piping
systems.
a.) Re-confirmation of removal of temporary items;
• Temporary piping
• Blanks
• Temporary strainers
b.) Restoration of permanent items;
• Orifice plates
• Spacer rings instead of temporary strainers
(2) A final leak test shall be carried out to verify the tightness of threaded joints, bolted
joints, packing glands and shaft seals.
For this purpose, the following joints are to be confirmed to be tight and not leaking.
a.) Joints of items removed during pressure testing and cleaning, such as in-line
instruments, piping, accessories and short pieces.
b.) Joints at which a blackout was used as isolation at pressure testing.
c.) Manhole flanges of equipment which were opened at cleaning.
d.) Joints to which a temporary piping was connected during testing and cleaning.
e.) Other joints at which tightness could not be verified at pressure testing.
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Method Statement
10.1.3. PVC Piping Installation Work

(1) General
This manual describes the implementation on PVC Pipe arrangements and welded
fittings to be used in the PVC line. The PVC line shall be used on fluid temperature of
60o C or less.
(2) Tools and Materials

a.) Tools
a.1)Vinyl Welding Machine (1 set of hot jet)
Specification : Working power : 230V, 50-60 Hz, Max. 860W
Hot blast temperature : 210-230 o C Max.
Hot blast pressure : 0.3 kgf/cm
a.2) Propane gas blow torch
Attachment : Pressure gauge, burner (with hose)
a.3) Puller ¾-1½ (for pipe inserting)
a.4) Saw : Hand Saw
a.5) Jig Saw
a.6) Sander and file
a.7) Knife
a.8) Scraper
a.9) Wooden hammer and others
b.) Materials
b.1) PVC Pipe (1/2 inch~ 28 inch) (16^ ~ 700^)
b.2) PVC Fittings (bend, tee, flanged, reducer, and others)
b.3) Adhesive AV Bond 52 (Under 2 ½ inch) (under 65 mm)
AV Bond 62 (Over 3 inch) (over 75 mm)
b.4) Acetone (For cleaning of the joined part)
b.5) Cloth (For cleaning of the joined part)
b.6) PVC Welding rod 3 ~ 4 mm Ø
(3) Implementation Method

In case of PVC piping, there are three types of joining methods i.e. cold setting joining,
hot-setting joining and Welding joining.
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Method Statement
This manual is explained about cold- setting joining (TS joining method) and
hot-setting joining (Sleeve joining method), as follows:
a.) TS Joining
In this case, TS joining are used and cold adhesion is adopted. The inside
surfaces are tapered.
a.1) PVC pipe cutting
The pipe shall be scraped to the given size and shall be cut by a saw in the
rectangular direction to the pipe axis.
a.2) Pipe edge bevelling (Section)

The outside edge of the pipe shall be bevelled at an angle of 45o in half of
pipe thickness with the sander or file.
a.3) Cleaning of Joining Part

Outer surface of spigot end and inner surface of TS joint shall be cleaned
with dry cloth to wipe off mud, moisture, oil, etc. and then sufficiently
cleaned up with acetone again.
Oily and extraneous matter will decrease the bonding strength so it must
be completely removed.
a.4) Confirmation of Insertion Depth

Confirm “The zero point” of TS joint by slightly inserting a specified length
of pipe into it. Then, the possible insertion depth shall be marked on the
surface with a colored pencil. As for the pipe more than 6” (150mm)
diameter, the pipe with the zero point shorter than 1/3 of joint adhesion
length shall be preferably heated at its extremity to enable it to penetrate
1/3 of the adhesion length.
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Method Statement
Insertion length to 0 (zero) - point is normally determined so that it

becomes 1/3 ~ 2/3 of the coupling length of pipe and joint.
a.5) Application of the adhesive
The adhesive should be thinly and uniformly (approx. 0.2 ~ 0.3 mm)
applied on the outer surface of the spigot end and on the inner surface of
TS joint with a suitable brush.
a.6) The pipe shall be inserted, as soon as the adhesive is applied on both
joining parts.
It shall be inserted to the stopper of TS joint. As the pipe of more than 3”
(75 nominal size) requires considerable force during insertion, it should be
carried out using a puller.
a.7) As the remaining adhesive layer on the joined end decreases the joining
effect, welding shall be carried out after cleaning of any adhesive films on
the surface.
a.8) After completion of the insertion, the two joined parts shall be held steadily
for 30~60 sec. to prevent them from being detached from each other
(slipping out).
(Holding time : 30~60 sec.)
(As the inner surface of TS joint is tapered, releasing the force immediately
after insertion may cause detachment of joined parts, therefore sufficient
care should be taken.)
a.9) Notes during adhesion
 TS Flange
Rectangularity of the pipe axis to TS flange surface, and parallelism of
TS flange to the bolt holes positions of mating flange shall be correctly
kept during adhesion.
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Method Statement
 TS elbow, TS tee (including TS socket with different dia. and TS socket

with same diameter).
Confirmation of the point where the bent angle and angle of the branch
pipe should be adjusted to the given angle.
If any dimensional error or other failures may occur in the adhesion, TS
joint should be pulled out from the pipe as rapidly as possible and after
adjusting the dimension and angle, the adhesive shall be applied again.
As the adhesive will progressively cure, it is difficult to pull out the pipe
after; re-adhesion shall be carried out as rapidly as possible. (Within 0
to 30 sec.)
b.) Sleeve Method

This is a pipe joining method without using joints (sockets), which is sorted as
follows:
One sleeve joining
TS sleeve joining
Two step sleeve joining
Zero sleeve joining
b.1) One Step Sleeve Joining

In this method the pipe is heat- softened and simultaneously adhesive is
applied and rapidly joined.
The detailed description of this method is not mentioned here because it is
rarely adopted in the plant piping works.
b.2) Two Step Sleeve Joining
In this method, a metal mold jig or a pipe with the same diameter is
inserted in the heat- softened pipe. After cooling and pulling out the
inserted mold jig or pipe, the shape of sleeve is formed. Then adhesive is
applied for pipe joining.
There are TS sleeve joining and zero – sleeve joining.
TS sleeve joining makes use of a metal mold jig with taper, and is adopted
most widely in the plant.
Zero – sleeve joining makes use of a pipe: therefore there is no taper.
This method is most widely adopted on the site; ashes can be carried out
using pipes only.
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Method Statement
Procedure on works:
 Pipe cutting
 Bevelling of the pipe edge
 Cleaning of joining part
The mentioned above shall be carried out just the same as TS joining.
 Marking of the insertion length
The insertion dimension of the female pipe shall be previously
determined and marked with colored pen or based on the following
Table 4.
 Application of lubricating oil
Grease shall be uniformly applied as lubricant on the insertion point of
the male pipe’s outer surface for easy insertion and pulling out.
 Heat softening of the female pipe
The female pipe shall be heated to the point slightly longer (30-60 mm)
than the insertion length with a propane burner or oil bath.
In case of propane burner, the pipe shall be uniformly heated as
rotating. Then the female pipe shall be immersed and heated in
polyethylene glycol bath in which the temperature should be controlled
in the range of 130- 5o C.
 Insertion of the male pipe
When the female pipe is softened, the male pipe shall be inserted to
the prescribed length chartered above into the female pipe.
At this moment, the insertion shall be carried out carefully so that both
axes of the male and female pipes are aligned with each other.
 Cooling of the Joined parts
After the insertion and joining operation, the male and female pipes
shall be cooled by water and cured.
 Marking of the mating mark
After completion of cooling and curing, the fitting mark and numbers
shall be marked on both pipes.
 Detaching of the female and female pipes
After the marking, they shall be pulled out by using a drawing jig.
When no jig is present, the edge of the female sleeve portion shall be
slightly hammered to detach the male pipe.
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Method Statement
 Cementing
Grease, oil, dust, etc shall be removed with cloth from inner surface of
the female pipe sleeve and outer surface of the male pipe.
Then, after cleaning with cloth soaked with acetone, adhesive should
be applied to the pipe and inserted into the female pipe.
At this moment, it shall be confirmed that the male pipe is perfectly
inserted to the sleeve length with the fitting marks getting aligned.
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Method Statement
General Pump Setting Work
1) GENERAL
(1) Scope
This specification covers the requirements for the installation of pumps that will be
used in the plant.
This specification may be applied to the installation of blower and other similar
machinery in general use. The general requirements which are common to the
installation works are covered by General Specification for Equipment Installation.
(2) Codes
(3) Units
Unless otherwise specified, metric units shall be used as the measurement system for
the drawings and documents to be submitted.
2) EXECUTION OF WORK
(1) Manufacturer’s Installation Specifications
In general, Paragraph 2.2 through 2.4 in this specification shall apply to the works.
However, the manufacturer’s installation manual as approved by the Bidder/Employer
shall be used instead, if applicable.
(2) General Requirements

General requirements which are common to each equipment installation shall be in
accordance with the General Specification for Equipment Installation.
(3) Installation and Alignment

a.) Installation and alignment of the pump shall be carried out as follows:
a.1) Carry out preparation works, such as chipping and fitting on the foundation
surface.
a.2) Prepare initial layout and set liners.
a.3) Place base plates on the liners and set anchor bolts.
a.4) Align and level the base plates.
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Method Statement
a.5) Fix the anchor bolts by pouring mortar into the anchor bolts.
a.6) Tighten provisionally the anchor bolts after mortar hardens.
a.7) Place the pump (frame, casing or the complete unit) in the base plate, align
the pump and tighten the anchor bolts.
a.8) Grout the base plates.
a.9) Re-check the alignment of the pump and couple the shafts after connection
with piping system.
b.) Preparation of the foundation surface, setting the liners, installation of the base
plate and pump, tightening of the anchor bolts and grouting of the base plate shall
conform to General Specification for Equipment Installation.
c.) Installation of the base plate and pump shall be carried out within the tolerances of
elevation, position, level and perpendicular alignment of the pump.
d.) Levelling shall be carried out at least on four corners of the base plate.
e.) The alignment of the pump shall be carried out based on the finished surfaces
which are nearest to the center of the shaft.
f.) When adjustment between shaft and coupling is required, the adjustment shall be
carried out on the coupling side, not on the shaft.
g.) The alignment of the pump shall be carried out until complete alignment of driving
and driven shafts is attained. On the alignment of the pump, deflection and face
deviation of the driving and driven shafts shall individually measure and it shall be
confirmed that values are within the tolerances specified and these data shall be
recorded properly.
h.) As a rule, the complete alignment of the driving and driven shafts shall be carried
out in accordance with the following procedures:
h.1) Measure the deflection of the shaft at the finished surface on the side of the
coupling with dial gage by rotating the shaft. Measure the face deviation
with feeler gage or dial gage for parallel alignment of both coupling faces.
h.2) Measure the deflection and face deviation at more than four equally
divided points on periphery of the coupling and confirm that measured
values are within the tolerances specified in the manufacturer’s standard.
h.3) Set the clearance between the couplings to the dimension specified in the
drawing. For connection with motor having plain metal bearing, align the
motor shaft to the magnetic center and adjust the clearance between the
two couplings.
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Method Statement
i.) Where dial gage is fixed with magnet base, the following cautions shall be taken
for minimizing errors caused by instability of measuring points:
i.1) Fix firmly.
i.2) Shorten the arm length as much as possible.
i.3) Use small type dial gage.
i.4) Put the measuring point of the dial gage right angle to the shaft surface,
pointing to the center of the shaft.
j.) After completion of alignment, confirm that the shaft can be rotated smoothly.
k.) After connection with piping system, make sure that the pump was connected
without counter force and recheck the alignment of the pump again. If the
alignment was affected by connecting the piping system, realignment shall be
made.
l.) After confirming the direction of rotation, the shafts shall be coupled.
(4) Trial Running

a.) Test run of the motor shall be performed with no load. It shall be confirmed that
vibration, sound and temperature of the motor is normal.
b.) After test running of the motor, the shafts shall be coupled. Recheck the direction
of rotation of the pump and motor.
c.) Trial running shall be performed with reference to shop test report
(5) Inspection
Inspection required in the works shall conform to manufacturer’s standard; inspection
shall comply with manufacturer’s inspection manual as approved by Bidder/Employer.
10.1.4. Submersible Pump Installation Work
1) General
(1) Scope
This specification covers the requirements for the installation of submersible pumps
that will be used in the plant.
(2) Codes
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Method Statement
(3) Units
Unless otherwise specified, metric units shall be used as the measurement system for
the drawings and documents to be submitted.
2) Execution of Work
(1) Manufacturer’s Installation Specifications
In general, Paragraph 2.2 through 2.4 in this specification shall apply to the works.
However, the manufacturer’s installation manual as approved by the Owner shall be
used instead, if applicable.
(2) Safety Precaution

Persons are not permitted to enter a confined space without specific precautions taken
in accordance with current safety standards.
(3) Guidelines for Installation

Construction layout must be in accordance with the measurements set in the
equipment standard dimensions table.
Determine the correct anchorage position of the discharge elbow, so the guide rails
when installed, will run parallel and plumb.
The construction of the concrete should be of sufficient strength to ensure a safe and
functional installation. The concrete foundation must have set before installing the
discharge elbow. The surface must be level and even.
Also take into account the upper guide rail brackets. Dimensions and space
requirements are based from the equipment standard dimensions table. Fix the upper
guide rail bracket by means of stainless steel anchor bolts at the edge of the sump
opening. Never fasten the brackets directly to a curved sump wall.
(4) Installation of Pump set with Guide Rails

a.) Description
In a stationary wet-well installation, the pump unit can be lowered and lifted out of
the pump sump by means of guide rails at any liquid level in the sump.
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Method Statement
Safely guided by 2 vertical guide rails, the pump slides into the sump or tank and
attaches itself automatically to the discharge elbow fixed at the bottom. Sealing
between the pump and discharge elbow is achieved by the weight of the pump. A
profile gasket between the pump and discharge elbow assures a water tight
leak-proof connection. There is no need to enter the sump for maintenance and
inspection of the pump.
b.) Installation of Guide Claw
Fit the guide claw to the discharge nozzle of the pump. Do not forget to place the
washers under the hex nuts. Nuts must be evenly tightened according to
instructions and to the required tightening torque.
c.) Installation of Mounting bracket / Discharge Elbow/ Bottom Guide Rail Bracket
Construction of the concrete foundation has to be of sufficient strength to ensure
safe and functional fixing of the guide rail system and the discharge elbow. Level
and anchor the discharge elbow. The guide rail must be installed absolutely
parallel and plumb.
Mount the bottom guide rail brackets on the discharge elbow in such a way that
standard dimension between the guide rails centerlines and the centerline of the
discharge elbow is complied with. Fix each bottom guide rail bracket the proper
tightening torque as required.
The installation of the bottom guide rails bracket is completed after tightening the
anchor bolts for the discharge elbow. Continue with the installation and fitting of
the discharge pipe to the discharge elbow.
Install the guide rails onto the bottom guide rails brackets at the discharge elbow.
Cut and fit the guide rails to required lengths. Make sure the guide rails are
absolutely plumb; it is important for the suspension and guidance of the pump
during installation. In case of deeper installations the scope of supply may include
intermediate brackets that will function as spacers between the guide rails. It
depends on the construction whether a support at the discharge pipe or sump wall
becomes necessary.
d.) Installation of Lifting Chain, Lifting Cable or Rope on Motor Housing
The chain of required sizes is attached to the top of the motor casing toward the
back and opposite the discharge nozzle using a shackle. Depending on the
motor and hydraulic combination, the pump will be suspended from this point with
an inclination of approx. 5-10 degrees.
74 / 149
Method Statement
This guarantees a problem – free lowering of the pump, provided that the
suspension point of the lifting equipment is directly above the pump.
Caution: Skewed lifting is to be avoided as it may cause jamming of the pump

guide claw to the guide rails.
e.) Installation of Pump

Please check, prior to the installation of the pump, standard clearance in between
the guide rail and the discharge pipe. Of utmost importance is the perfectly vertical
installation of the guide rails. This work has to be done prior to the introduction of
the pumped liquid into the sump to guarantee a smooth lowering and lifting of the
pump. Afterwards, correct assembly slips or misalignments if any. Guide the
pump from above over the bracket, the pump will attach itself automatically to the
discharge elbow and will be connected to the discharge pipe and ready for
operation. Attach the lifting chain to the hook on the upper guide bar bracket or
at the edge of the tank in an appropriate manner.
(5) Inspection
Inspection required for the works shall conform to manufacturer’s standard; inspection
shall comply with manufacturer’s inspection manual as approved by the Employer.
10.1.5. Welding Works – Steel Pipes
1) General
(1) Scope
This specification covers the requirements for field welding work on carbon steel pipes
and stainless steel pipes.
(2) Codes
Unless otherwise specified, the welding and other criteria covered by this specification
shall be in accordance with the Code for Chemical Plant and Petroleum Refinery
piping, ANSI B31.3, latest edition.
75 / 149
Method Statement
2) Welding Method
(1) Welding Method
Welding method shall be qualified in accordance with ASME SEC. IX, and the
following are generally accepted for welding of pipes;
a.) Shielded metal Arc (SMA) Welding
b.) Gas Tungsten Arc (GTA) Welding
(2) Application of Welding Method
Butt circular welding shall be done in accordance with the Table I, attached;
The Shielded Metal-Arc Welding (SMAW) process shall be used for fillet welding.
(3) Welder
a.) Qualification
The welder and welding operator shall be qualified by in accordance with ASME
Section IX. Each qualified welder and welding operator shall have assigned
identification numbers, letters, or symbol, which shall be used to identify the work.
Records of Performance Qualification shall be prepared and maintained and shall
be available when requested for verification by the inspector or customer
representative.
(4) Welding Electrode

Selection and handling of the Welding Rods shall be as follows:
a.) Selection of Welding Rods
The core wire, coating and deposited metal shall be of the AWS grade or
equivalent. Selection shall be made in such a way that they are suitable for the
base metal at weld zone.
Table 2 shows the applicable welding rods.
b.) Control of Welding Rods

b.1) Drying
The welding rods of good storing conditions shall be employed. If the
welding rods contain moisture, they shall be dried in accordance the
conditions shown in Table 3.
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Method Statement
TABLE 3: Drying Conditions for Welding Rods
Temperature
Welding Material Hour
( ْ C)
Coated Welding Rod for Stainless Steel 200 - 250 1-2
Low Hydrogen Type

Coated Welding Rod
(AWS E6011/E6013 or 300 - 350 1
for Carbon Steel
Equivalent)
b.2) Carrying the Coated Welding Rods

The coated welding rods shall be carried in portable dyer or in a casing to
prevent absorption of moisture. The maximum amount of take out for one
time shall be about five (5) kgs. If the welding rods are left in the air for over
2 hours, they must be dried again in accordance with TABLE 3, with only
two returns for reheating shall be permitted. Welding rods shall not be
damaged and opened during transportation and storage.
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Method Statement
(5) Groove Treatment

a.) Groove Shape for Butt Welding
a.1) Unless otherwise specified, end preparation for butt weld shall be in
accordance with following figure:
1.6 to 2mm
PIPE WALL THICKNESS

t ≤ 3mm
60 +/- 0 to 10 deg.
t=1.6 +/-
t
0.8mm
2.0 to 3.6mm
PIPE WALL THICKNESS

3mm< t ≤ 19 mm
b.) Groove Shape for Branch Piping

Groove shape for welded pipe to pipe branch connections shall be in accordance
with Fig. 1a and 1b.
O-let type connection shall be joined as shown in Figure 2.
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Method Statement
(6) Fitting Accuracy of Butt Joints

a.) Tolerable Misalignment between Both Plates of Butt Welds
a.1) Radial misalignment at the joint end of piping components shall be limited
as follows:
Misalignment (x)
= 1.5 mm or ¼ the wall thickness, whichever is less
(7) Welding Work

a.) Temporary Assembly
a.1) Tentative Assembly
Tentative Assembly will be made by using jigs to prevent damage on the
groove root.
a.2) Tack Welding
Tack welding may be done under the following conditions:
 A qualified welder shall be engaged in the welding work.
 The welding rod for the first layer shall be used for the tack welding.
 The length of tack welding bead shall be the minimum necessary size.
 Both ends of tack welds shall be ground smoothly before welding the first
layer.
b.) Regular Welding
Welding shall be done in flat position if possible, and the following requirements
shall be satisfied:
b.1) General Welding
The spatter-prevention agent may be used if necessary.
In the case of coated arc welding, argon back seal shall not be used if not
specified. In the case of TIG welding argon back seal shall be applied for
stainless steel and shall not be applied for other materials unless specified.
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Method Statement
b.2) Limitations on Imperfections in Welds

Limitations on Imperfection in welds shall be as stated in ANSI B31.3,
paragraph 327.4.1 and 327.7.2, unless otherwise specified below.
No finishing shall be applied on the bead reinforcement. The tolerance shall
be shown in Table 4.
TABLE 4: Tolerance of Bead Reinforcement
Reinforcement Height (mm)
Welds without Radiographic Welds with Radiographic

Wall Thickness of Pipe (mm)
Inspection Inspection
Below 4.8 Below 2.4 Below 1.5

Over 4.8 below 12.7 Below 3.2 Below 1.5
Over 12.7 below 25.4 Below 4.0 Below 2.5
Maximum allowable projections of weld metal into the pipe bore at welded
butt joints are as follows:
 Projections shall not exceed 3.0 mm.
 Imperfections exceeding these limitations are considered defects.
c.) Slip–on Flange Welding
In principle, fillet welding on both sides shall be made in accordance with Figure 3.
d.) Socket Welding
In socket welding, proper clearance (approximately 1.6 mm) shall be provided at
the end of the pipe.
80 / 149
Method Statement
(8) Repairs after Welding

a.) General
In case defects were found in the welded zone after completion of the welding, the
defects shall be removed and repaired.
Limitations on imperfections and welding methods and extent of required
examination for repaired welds shall be the same as for the original welds.
Repair works shall be done by a qualified welder.

Repair Procedure:
Under cut and concave root shall be repaired with build–up welding.
For such defects under the surface of welding such as blow hole, slag inclusion,
etc., the defects shall be removed completely by means of grinder, arc air gausing
or chisel and re-welding shall be applied.
If cracks were found in the weld zone, the defect shall be removed by means of
grinder. After checking that the defect has been removed completely, re-welding
will be applied.
Repair welding shall be done in accordance with the procedures of paragraph 7 in

“Welding Work”.
(9) Non-Destructive Test

When required by the client and / or by the code, non-destructive testing shall be
conducted on completed welds.
(10) Finishing
Inside the circumferential weld bead shall not have any burr or fragment of welding rod
and all adhering substances shall be removed as far as possible.
Spatter, slag, etc. of welded part shall be thoroughly removed from the metal surface.
Record including the following information shall be prepared for each welding joint of
Inspection Class A and B Piping.
a.) Name of welder
b.) Kind of welding rod used
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Method Statement
c.) Date of welding

d.) Record of repaired weld zone (defect, repairing method, place, data, name of
welder, engineer)
e.) Post-welding heat treatment (data, heating method, temperature curve of the
heated object) if required.
f.) Other necessary information
(11) Tables
a.) Table 1 – Application of Welding
Piping Welding Process

Remarks
Material Size Root Pass Weld Out
SMA SMA
1/2” to 2” Welding Welding
Carbon Steel
SMA SMA
3” and above
Welding Welding
Stainless SMA SMA
All Sizes
Steel Welding Welding
82 / 149
Method Statement
b.) Table 2 – Coated Arc Welding Rod
Base Metal Welding Rod

Equivalent Welding
Rod Available in the
Market
Pipe Remark
Representativ AWS
Material Niho s
e Composition
n
WIP WELD
Weld
Rod
WEL
Stainles SUS 304TP 18Cr-8Ni E308 WIPWELD308
308
s Steel
Pipes SUS 16Cr-12Ni-2M E316 WEL
WIPWELD316
316LTP o Low Carbon L 316L
SGP-B, E
SGP-B(G) E WIPWELD110
Carbon
STPG38-E, 6011 0
Steel
S E
Pipes WIPWELD130
STPT38-S 6013
0
STPY41
Transitional Joints between WEL

Others E 310 WIPWELD310
Carbon Steel Pipes and 310
Stainless Steel Pipes
10.1.6. Electrical and Instrumentation Work
1) General
Design and construction of electrical equipment and system is performed basically
according to project standard specified by the Employer and the local standard or
regulations in Sri Lanka. Manufacturing of electrical system will be done in Sri Lanka as
much as possible by the qualified subcontractors having sufficient experiences and skill.
83 / 149
Method Statement
All the instrument equipment will be supplied from the countries outside Sri Lanka to
construction site except the standard instrument equipment and construction materials.
Custody of special electrical and instrument equipment shall be made at air-conditioned
storage house in order to avoid any deterioration of electrical and electronic parts.
2) Installation of power supply system and cabling

Installation of high tension switch gear, transformers, motor control panels, etc. will be
basically made after the civil and foundation work has completed.
Cable rack and ducts are installed with the supporting pitch of 2 meters or smaller.Conduit
pipes are used for connection of cables to motors and equipment.
3) Instrumentation
Instruments to be assembled with the pipe lines are installed at a time of piping work by
piping people and those to be installed onto the equipment will be set by the instrument
engineers from subcontractor under the supervision by the Contractor’s instrument
engineer.
Control cables for instrumentation are laid separately from the power cables.
Installation of Electrical Equipment
GENERAL
Installation of low voltage switch gear, motor control centers, instrumentation panels, cable
tray/ladder, etc. will be basically made after the civil and foundation work has completed
and shall be carried out in accordance with the approved drawings and erection manual.
A crane or forklift will be needed to lift up all the electrical equipment to set in to a desired
location and purpose. Proper handling of the equipment should apply to avoid damaging
the equipment and the components itself.
84 / 149
Method Statement
RECEIVING, HANDLING AND STORAGE
Receiving
Before and after unloading the electrical equipment, inspect its section and unit exterior for
evidence of damage that may have been incurred during shipment. If there is any indication
has been mishandled or shipped on its back or side, remove the draw out units and make a
complete inspection of the internal structure, bus bars, insulators and unit components for
possible hidden damage. Report any damage found to the carrier at once.
Handling
Handle the electrical equipment with care to avoid damage to components and to the
enclosure or its paint finish.
Keep the electrical equipment in an upright position.
Insure that the moving means has the capacity to handle the weight of the electrical
equipment.
The electrical equipment should remain secured to the shipping skid until it is in final
location.
Exercise care during any movement and placement operations to prevent falling or
unintentional rolling or tripping.
Lifting angles for handling by overhead crane are bolted to the top of each shipping section.
Handling by overhead crane is preferable but when crane facilities are not available,
the electrical equipment can be positioned with a fork-lift truck or by using rollers under
the shipping skid.
Fork-lift Truck
Electrical equipment’s are normally top and front heavy. Balance the load carefully and
steady, as necessary, while moving. Always use a safety strap when handling with a
fork-lift.
Storage
When electrical equipment cannot be installed and place into operation immediately upon
receipt, take steps to prevent damaged by condensation or harsh environmental conditions.
If the equipment cannot be installed in its final location, store it in a clean, dry, ventilated
building, heated to prevent condensation, and protected from dirt, dust, water, and
mechanical damaged.
85 / 149
Method Statement
ELECTRICAL EQUIPMENT INSTALLATION

All electrical equipment should be installed in a place with no vibration is present.
Before any installation work is begun, consult all drawings furnished by the
supplier/manufacturer as well as all applicable contracts drawing for the installation.
Give particular attention to the physical location of units and their relation to existing or
planned conduit, bus ways, etc.
Locate the electrical equipment in the area shown on the approved building floor plans. If in a
wet location or outside the building, protect the equipment from water accumulation
within the enclosure.
Since the electrical equipment are assembled at the factory on smooth and level surface to
assure correct alignment of all parts, the equipment should be securely mounted on a
level surface. The foundation must be true and level, or the bottom frames must be
shimmed to support the entire base in a true plane. If sills are grouted in concrete, the
mounting bolts should be screwed in place and remain until the concrete hardened.
For bottom entry, position the equipment so that the conduit stubs or floor opening are
located in the shaded area shown on the equipment floor plan drawing. The shaded
area represents the open space available for conduit entry through the bottom of each
section. If optional bottom plates are supplied, the plates may be removed and drilled
for conduit entry.
Use the channel base, check and adjust the level using liner wedge then use anchor bolt to
fix the channel base.
After the channel base is set, mount the electrical equipment on the channel base, with the
drilled hole available on the channel base and the electrical equipment use bolts and
nuts and tighten it. Check alignment of panel horizontal and vertical.
When all wiring and adjustments are complete close all unit and wire way doors.
In damp indoor location, shield the equipment to prevent moisture and water from entering
and accumulating.
Unless the equipment has been designed for unusual service condition, it should not be
located where it will exposed to ambient temperatures above 40°C (104°F) corrosive
or explosive fumes, dust, vapors, dripping or standing water, abnormal vibration, shock
or tilting
86 / 149
Method Statement
PIPING AND WIRING ON ELECTRICAL EQUIPMENT
Piping
Install conduit in such a manner as to prevent water from entering and accumulating in the
conduit or into the enclosure. Eliminate sags in conduit. Have the conduit enter the
equipment in the areas designated for conduit entry on the plan views.
Wiring
Please be guided with the wiring diagram, termination diagram and single line diagram this
is to avoid incorrect wiring.
Use conductor with a rating of 75°C or higher, but regardless of the insulation temperature
rating select the wire size on the basis of 75°C wire ampacity. Using a higher
temperature wire ampacity table often results in a smaller cross section of copper
available for carrying heat away from the terminals.
Install insulated wire and cable at a temperature sufficiently warm to prevent the insulation
from splitting.
When more than one conduit is run from a common source or to a common load, be sure to
have each phase and the same number of conductors per phase. If the phase
conductors are not distributed uniformly, eddy currents will be generated in the steel
between the conduits.
Locate the equipment to avoid physical damage and to avoid overheating. Secure
incoming power lines in a manner adequate to withstand the forces which will act to
separate the conductors under short-circuit conditions. Use the cable ties furnished in
both horizontal and vertical wire ways to support the load and interconnection wire.
Use a shielded communication cable to protect very low signals transmitted to or from
a computer or programmable controller.
Verify the compatibility of wire size, type, and stranding with the lugs furnished. Where they
are not compatible, the wire or lugs accordingly. If crimp lugs are used, crimp with the
tools recommended by the manufacturer.
All fields wiring to control units should be made in accordance with the wiring drawings that
are furnished with the equipment. Load and control wiring can be wired trough lower
horizontal wire ways.
87 / 149
Method Statement
CABLE TRAY INSTALLATION
GENERAL
Cable tray/ladder system shall comply with IEC 61537, manufactured from not less than
2mm thick perforated hot dipped galvanized steel material.
COMMON TOOLS FOR CABLE TRAY INSTALLATION
The following tools are commonly used for installation of cable tray:
• Metal cutting saw
• Touch-up material
• Screwdriver
• Drill with bits
• File
• Open end wrench
• Nylon cord or laser
• Sealant for cut edges
• Leveling device
• Tape measure
• Torque wrench
• Ratchet wrench
• Appropriate safety equipment
CABLE TRAY SUPPORT INSTALLATION
Do not cut or drill structural member like beams, columns and steel trusses.
In order to install cable tray supports like threaded rods, first find the require elevation from
the floor to the bottom of the cable tray and established a level line with a laser or a nylon
string.
88 / 149
Method Statement
Horizontal and vertical span for wiring duct:

WIDTH OF DUCT MAXIMUM DISTANCE BETWEEN SUPPORT
2400 mm Below 300 mm
2000 mm 300 – 600 mm
1800 mm Over 600 mm
CABLE TRAY INSTALLATION PROCEDURE

Ensure that the proper materials are available and are approved for use, as well as the
approved drawings.
Verify site access/ routing and mark support location.
Obtain work permit, if required.
Install/erect proper scaffolding and ladders where ever required during erection/installation of
supports and cable trays.
Fix the support on the natural structures, by drilling appropriate holes.
Fix the vertical ladder trays channel on the support.
The cable trays and ladders shall be installed in such a way that, as often as possible the
cables can be laid directly in place rather than being pulled through.
Clearance shall be maintained/ observed during cable ladder or tray installation as per
specified on approved drawing and specifications.
Cable trays and ladders shall be supported adequately and fixed bolt and clamps as per
specifications and drawings and applicable standards.
Sharp edges of trays and ladders shall be reamed to smooth and paint.
Touch as paint shall be applied to the scratches / damaged surface of cable trays and
ladders.
Care to be taken to avoid corrosion and rust formation during installation.
Connect earth bonding.
Test earth continuity.
Ensure that cable trays and ladders are erected correctly, inspected and approved by the
contractor/Engineer prior to cabling.
Support fabrication.
The support will be prefabricated on the workshop of approved supplier using appropriate
approved material cut according to the length show on the drawings and after that, the
bracket will be fixed with anchor bolt to the channel.
89 / 149
Method Statement
CONDUIT INSTALLATION
GENERAL
Approved conduit system shall comply with IEC 614. That all steel conduit and fittings shall
be hot dipped galvanized. Use steel conduit if exposed installation and PVC conduit if
embedded in concrete walls and slab.
Installation must be performed in a neat and workman like manner and shall be inspected
by engineer’s representative and approved before any cable is drawn.
Messenger wire minimum of 1.2mm shall be inserted into spare conduit.
CUTTING AND THREADING STEEL CONDUIT

Use a standard pipe threader. The threads shall be cut full and clean using sharp dies.
Do not use worn dies.
To adjust the dies, loosen the screws or locking collar that hold the cutting dies in the head.
When the screws or collar are loosened, the dies should moves freely away from the
head.
Screw the die head onto the threaded nipple or factory-threaded conduit until the die fits the
factory thread. If the die head has an adjusting lever, set the head to cut a slightly
oversized thread.
Tighten the screws or locking collar so that the dies are tightly held in head.
Remove the set-up piece of threaded conduit. The die is ready for use.
After adjusting the dies cut the conduit with a saw or roll cutter. Be careful to make a straight
cut. After cutting and prior to threading, ream the interior and removed sharp edges
from the exterior.
PROTECTION OF FIELD CUT THREADS

Protection is necessary and the conduit is threaded in the field, the thread shall be coated
with an approved electrically-conductive, corrosion resistant compound. Zinc-rich paint or
other coatings may be used.
CUTTING STEEL & PVC CONDUIT

Cutting- Use a fine tooth saw to cut conduit. A hacksaw can be used on all sizes of conduit
or a speed cutter may do.
90 / 149
Method Statement
BENDING STEEL CONDUIT

A full shoe or universal bender is the preferred bending tool for steel conduit. Limit the
bending to grade sizes. To make hand bending of trade size, use a two position foot-pedal
bender. This allows more weight to be applied for leverage.
Trade size bigger require a power bender or a mechanical ratchet-type bender.
ATTACHEMENT TO BOXES AND SUPPORT

Properly align the raceway, fittings, and knockouts to provide secure mechanical and
electrical connections. Allow sufficient conduit length to complete engagement of the
conduit and fittings at joints and entries.
Conduit bushing shall not be used to secure threaded steel conduit to a box or enclosure. A
locknut shall always be assembled between a conduit bushing and inside of the box or
enclosure.
Where locknut is provided with fittings at the means of securement to a box or enclosure,
the locknut is to be secure by hand-tightening to the enclosure plus ¼ turn using an
appropriate tool.
Do not rely upon locknut to penetrate nonconductive coatings on enclosure. Coating shall
remove in the locknut contact area prior to raceway assembly to assure a continuous
ground path is achieved. Touch up bare area as needed after installation.
For outdoor type installation weatherproof boxes and accessories shall be use as agreed
on site by the Engineer as per also indicated in the specification or on the approved
drawing.
VERIFICATION OF INSTALLATION
After the raceway is fully installed and supported, and prior to installing conductors in a
raceway, all fittings and locknut shall be re-examined for secureness.
SUPPORT OF STEEL CONDUIT

Support and securely fasten all raceways in place in accordance with the electrical code
requirements and shall be approved by the engineer.
91 / 149
Method Statement
Steel Support Interval
SIZE INTERVAL
20 mm Ø 1.2 m
25 mm Ø 2.0 m
32 mm Ø 2.5 m
SUPPORTING
Follow all code requirements for spacing of supports and frequency of securing steel
conduit. The requirement to securely fasten raceways within the specified distance from
each termination point includes, but it is not limited to, outlet and junction boxes, device
boxes, cabinets, and conduit bodies. Each raceway shall be so secured. Do not omit any
supports.
SECURE AND FASTENING

Raceways are permitted to be mounted directly to the building structure. Assure that
supporting means and their associated fasteners from which they are supported.
Raceways support shall be installed only on conduit of the trade size indicated on the
fitting or its smallest unit shipping container.
Steel conduit exposed on masonry surfaces, plaster, drywall or wood framing members:
one-hole straps, two-hole straps, conduit hangers, or similar products intended for the
purpose, securely fastened with appropriate hardware.
Steel conduit mounted on metal framing member: one-hole straps, two-hole straps, conduit
hangers, or similar products intended for the purpose, fastened with metal screws or
rivets, beam clamps, or similar means for extra support.
Steel conduit suspended below ceilings or structural members such as beams, columns, or
purlins, or in ceiling cavities: These raceways are best supported by lay-in pipe
hangers. The pipe hangers are to be supported by threaded rod, which is, in turn,
fastened in place by beam clamps or similar devices. Strut type channel can also
provide secure support. Raceways are not permitted to lie on the suspended ceiling.
Support at new concrete pours: In these cases, place approved channel inserts into the
concrete pour. Raceways will be mounted to the channel later in the construction
process.
92 / 149
Method Statement
COROSSION PROTECTION
Steel conduits are typically galvanized to provide excellent corrosion protection.
Sometimes supplementary corrosion protection is required if the installation is in a severe
corrosive environment.
INSTALLED IN A SOIL
Where installed in contact with soil, steel conduit and associated fittings require
supplementary corrosion protection if soil resistivity of less than 2000 ohm-centimeter and
has confirmed that the soil is extremely corrosive.
Also, warning sign or warning tape shall be provided on the ground to indicate that there is
a buried conduit.
TRANSITION FROM CONCRETE TO SOIL

Where steel conduits emerge from concrete in soil, it is recommended that the protection
be provided on each side of the point where the raceway emerges. Paint, tape, and shrink
tubing are one of the examples of protection.
INSTALLED IN CONCRETE SLAB

Where installed in a concrete slab below grade, determine if steel conduit requires
supplementary protection for that location. In general steel conduits do not require this
supplementary protection.
PULL BOXES
Pull boxes and fittings shall be plated by melting zinc or coated with-preventive paint and
shall be sized correctly to accommodate the connected conduit and all required conductors
run through.
WIRING AND CABLING
GENERAL
All cable routes must be authorized by the supervising officer for the project.
All cable installed must comply with the BS standard. All power / control cable shall be
600/1000V rating.
93 / 149
Method Statement
All wiring/cabling shall be done after the roughing-inns and cable tray installation and it
must follow the wiring schedule and termination diagram.
Wiring and Cabling of Power, control and instrumentation will be done via cable tray/ladder
and conduits in a workman like manner and separator will be provided to cable tray to
separate power cable to control and instrument cable.
INSTALLATION
Bending of the cable shall keep to an absolute minimum.
Consider the minimum bending radius of the cable at any point, with zero stretching stress,
following installation.
Cables should not be stressed by over-tight cable ties. Ties should be used to segregate the
cables and managed them, not to flatten or change the geometry.
Cable ties should only be used in such circumstances to loosely bundle the cable runs for
ease segregation and identification and identification to various works areas.
When cables pass through holes in walls or floors precautions must be taken to remove the
sharp edges, which will damage cable beyond repair.
Where possible, to minimize the effect of power cables on data cable when installed in three
compartment trunking, it is recommended that the power cables occupy one of the
outer sections and other data cables.
Cable rack and ducts are installed with the supporting pitch of 2 meter or smaller.
Cables are not cast directly into concrete. It should have conduit or suitable raceways.
Conduit pipes are used for connection of cables to motors and equipment.
Cabling works in the cable pit shall be arrange suitable separator and support to separate
cable route between power cable, control cable, and instrumentation cable.
Where cable pass through fire rated walls of floors a fire barrier or fire rated sealing
compound shall be used.
ROUTING OF CABLES THROUGH CEILING VOIDS
All cabling must be secured through ceiling voids.

Cables may not be tied to ceiling supports or rest on the false ceiling.
94 / 149
Method Statement
CABLE TRAY TRUNKING

Remove cover from tray / trunking and put sealant where trunking passes through wall.
Replace cover once installed and attached identification label on trunking for later
reference.
INSTRUMENT INSTALLATION
SCOPE
This specification describes the practices that shall be employed and the standards of
workmanship that shall be required for the installation of instrumentation.
CODE
The applicable codes and standards shall be indicated in specific job requirements.
GENERAL REQUIREMENTS
Quality assurance, Inspection and testing shall be undertaken in accordance with
installation CONTRACTOR’S Quality Assurance System/ Quality Plan, requirements of the
project specification and reference International Codes and Standards.
INSTRUMENT LOCATION AND SUPPORT

Instrument shall be located in accordance with the detail drawings and with due regard to
accessibility and maintenance activities. Vent, drains and filling point shall be sited to
minimize the impingement of process fluids on instrument equipment and cable.
Instrumentation requiring operator access shall be mounted at a height of 1400 mm from
grade or platform.
Where field indicators are specified in association with blind transmitters, the field indicator
shall be located so as to be visible from associated control valve or final element,
unless otherwise noted on the P & I diagrams.
When installing instruments, allowance shall be made where necessary for any tracing,
insulation and housing which may be required.
Instrument field supports, junction box frames, etc. shall be prepared and finished in
accordance with detail drawings. Minor brackets and supports shall be stainless steel.
All instrument equipment shall be mounted and supported such that it is free from vibration
and misalignment.
All local panels, JB frames, etc. shall be labeled as required. Where equipment is mounted at
95 / 149
Method Statement
grade, the supports shall be grouted such that any water is shed.
Instrument located outdoor, and subject to severe ambient temperature including moisture
and corrosion shall be protected by installation in a weatherproof housing or IP 68
similar protective enclosure.
INSTRUMENT ACCESSIBILITY
All instruments shall be accessible for servicing from floor level, walkways, permanent
ladder or platforms. Above 2m instrument shall be provided with permanent access.
PIPING OF INSTRUMENT
One or two single pipes or tubes may be supported by dedicated heavy duty channel
section if other support is not available.
Tubing shall be fastened to support at regular intervals with non-corrosive fixing to prevent
sagging, or misalignment.
INSTRUMENT CABLING
GENERAL
Instrument cable shall be installed in such a manner that the design requirements for the
contract in terms of safety, reliability, access, etc. are realized. The main points of the
design philosophy are given below and all installation method shall take account of this
philosophy.
DESIGN PHILOSOPHY
All outdoor cable shall be armoured. All cables shall be supplied as specified in agreed
cable specification.
Multicore cable shall be sized such that they contain a minimum of 20% spare conductors
at the completion of contract design.
Junction boxes shall be dedicated to one signal category only.
Intrinsically safe circuit and non-intrinsically safe circuit shall not be contained within the
same cable or marshaled in the same junction box.
96 / 149
Method Statement
All equipment containing an electrical signal or power supply shall be earthed for personnel
safety reasons and for minimizing electrical interference. This includes enclosures, cables,
cable tray and conduit.
All cabling shall be protected against mechanical damage, chemicals and heat. In general,
underground cabling and cabling run on ladder rack and tray will meet this requirement if
installed in accordance with the contract drawing and provided attention is paid in detail
routing.
FIELD CABLE AND JUNCTION NUMBERING

The number of every cable and junction boxes shall follow that shown on the detail drawings.
Main cable numbers shall consist of a prefix defining the signal category followed by
sequential number.
Main junction box number is derived from the main cable number prefixed JB.
Secondary multicores (i.e. Multicores between the main JB and secondary JB) are derived
from the main cable number with suffix letter.
CABLE SEPARATION
Control cables for instrumentation are laid separately from the power cables.
Instrument cables carrying more than10 amps shall be treated as power cables.
CABLE INSTALLATION
All cables from control buildings to junction boxes, from junction boxes to individual
instruments, and other cables, shall be supported by a suitable cable support system.
Routes which cross walkways shall provide minimum headroom of 2.5m. Routes which cross
roads or areas requiring vehicular access shall provide minimum headroom of 5.5m.
Where routes pass through the floor of a structure, mechanical protection in the form of a
metal sleeve shall be provided.
Cables within control rooms shall be routed under floor. Where cables are routed above the
floor they shall be trunking or conduit.
Under floor cables shall be installed on ladder rack and cable tray. The general requirements
for above ground installations in the field are applicable.
97 / 149
Method Statement
CABLE INSTALLATION – GENERAL

Cables shall only be terminated in instruments, junction boxes or other approved equipment.
No intermediate cable joint are permitted.
Where cables are pulled prior to installation of packaged units, modules, etc., care shall be
taken to ensure that cables are adequately protected.
When installing cables the radius of all bends shall exceed the minimum bending radius
specified by the cable manufacturer.
Installation, terminating, jointing and testing of fibre-optic and co-axial cabling be strictly
accordance with manufacturer’s instruction.
Cables connected to instruments shall be installed with loop of cable to provide sufficient
slack for re-making the cable connection if the instrument is removed and to allow for
removing the instrument without electrical disconnection.
CABLE GLANDING
All cables in the field shall have gland with correctly certified cable glands in accordance with
hazardous area classification.
Cable glands are not normally required for cables in equipment rooms of buildings, but may
be required at required at other locations within the buildings.
All gland installation shall maintain the IP rating of the associated equipment.
WIRING TERMINATIONS
All terminals shall be screw clamp terminal clamp type where the screw is not direct contact
with the wire. Terminal may incorporate test sockets if necessary. Power supply
terminals and all terminals shall be fitted with protective covers and warning labels.
Power supply terminals shall be fitted with partitions between adjacent terminals.
Normally only one conductor shall be terminated in each terminal. Common connections
shall be made as far as possible using the terminal manufacturer’s standard bridging
arrangement. Where connection of 2 wires into one terminal unavoidable, two
flat-bladed crimps shall be pin type crimps shall not be screwed into one terminal.
Sufficient slack wire shall be left looped at terminals to allow for re-making of terminations.
All spare cores in multi-core cable shall be terminated. Sufficient terminals shall be fitted in all
equipment to facilitate this.
Conductors shall be ferruled with the number of the terminal to which they are connected.
98 / 149
Method Statement
LABELS
Every item of instrument equipment for which an identification reference is allocated shall be
provided with engraved label. This label shall be in addition to any manufacturer’s
wired-on tags or nameplates.
Labels shall normally be engraved plastics. Dimensions, sizes, colours, engraving details
and method of fixing shall be as determined by the contract drawings or as agreed with
the site engineer.
Labels for individual instrument shall be fitted adjacent to the instrument such that the label
remains in place if the instrument is removed. Labels for other equipment shall
normally be fitted on the equipment.
GROUNDING SYSTEM
GENERAL
All exposed metal frames of all electrical system, apparatus and equipment that are part of
the electric circuits, neutral of transformer, etc., shall be grounded to ensure the public and
personal safety.
Refer to approved drawings and consult Engineer for the final location and installation of
grounding rods.
MATERIALS USED FOR GROUNDING SYSTEM

Grounding conductor
Grounding Plate
Grounding Rod
Connectors
Exothermic powder if necessary
PVC Conduit
99 / 149
Method Statement
MATERIAL REQUIREMENT
Steel rod use shall meet the requirement of copper clad steel rod, 16 mm Ø, and 1.5 m
length.
The leading edge of the ground rod shall be provided with sharpened point, and the other
shall be beveled.
The ground rod shall be free from badly formed, cracked or other defective structure.
A grounding plate shall be 90 cm, 1.5 thickness copper plate.
Annealed stranded copper conductor type shall be used as a grounding conductor.
GROUNDING WORKS
Locate the grounding pit. This is where the ground rod to be installed.
Drive ground rod into the ground pit until the coupler is just above ground.
Measure the ground resistance of the ground rod before connecting the grounding conductor.
A minimum system grounding resistance of 5ohm shall be maintained.
Connect the ground conductor into the ground rod by means of compression type connector
or by exothermic welding if necessary.
Soil excavation and backfilling works shall be executed by a civil works.
Lightning protection and instrument grounding shall be done by a separate common
grounding.
Grounding for transformer neutrals and lightning arrester, grounding rod shall be installed
for interconnections with grounding mesh
FIELD TEST
A notification will give in advance to carrying out any tests of the electrical equipment and field wiring so
that the company representative is able to witness equipment and cable support mounted within the
panel/in the field, but not wired. Fully wired and ready to test.
Prior to starting any test it is required to double check the installation, electrical devices and
instrumentation are strictly in accordance with the manufacturer’s specification, electrical
and instrumentation drawing.
The test result shall be submitted to the company representative:
100 / 149
Method Statement
Individual test
• Visual inspection
• Insulation resistance for all equipment and wiring/cable
• Withstand voltage test of insulation oil
• Circuit continuity test
• Relay checking
• Polarity test
• Phase rotation test
Completion test
• Visual inspection
• Insulation resistance for all equipment and wiring/cable
• Withstand voltage test of insulation oil
• Circuit continuity test
• Relay checking
• Polarity test
• Phase rotation test
• Operation test of each equipment
• Interlock sequence test
• Indication test
• Fault alarm test
Installation of SCADA
1) GENERAL
The SCADA system takes over, is produced, and delivered to the procedure for of this chapter.
2) Workflow
The work flow of the SCADA making is composed of the following item.
• Basic Engineering
• System Engineering
• Detail Engineering
• Documentation
• Erection (Supervision)
• Commissioning and Training.
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Method Statement
3) Engineering
The following document is submitted at the first stage.
• Overall DCS concept system configuration with network topology, operator place
definition,
• MHI concept (Machine Human Interface System) operation and monitoring concept,
hierarchy of mimic
• Diagrams, data archiving and retrieval, report functions, access control, graphic
layout concepts,
• Colors and symbols, etc.
• Concepts for power supply, shielding, earthing and lightning protection
• Wiring concept
We will submit the detailed drawing and the document at the final documentation.
4) Factory Acceptance Test

SCADA are subject to a series of rigorous hardware and software test procedures in the
factory. Before shipment to the plant, the I&C cubicles will be submitted to the system
integration test at the test facilities of Vender. All tests will be executed according to SCADA
Vender standard test procedures and consist of:
• System integration test
a) Assembling the various components from engineering and manufacturing departments to
systems,
b) Respective subsystems (e.g. applications, assemblies, bus systems).
c) Check of cubicles (power supply, monitoring, bus connection as well as voltage test and
wiring check).
d) Testing of bus communication and operation network
e) Loading of the application software into the system
f) Documentation, respective archiving of the system status before shipment
g) Test reports
• Functional test, consisting of:

a) Sample testing of selected I/O-signals.
b) Testing of project specific standard functions
c) Testing and simulation of selected complex control functions
d) Systematic and process oriented final check based on the task definition and project
specific
102 / 149
Method Statement
e) Documentation prepared by ABB.

f) Documentation, respective archiving of the system status before shipment
g) Test reports
• Witnessed test
5) Erection
After the equipment is carried, the following work is executed in the site.
• Connection of the power supply cables to the process control cubicles
• Connection of the earthing to our cubicles
• Installation/connection of our cubicles
• Installation/connection of control room equipment (HMI, printers, etc.)
• Installation/connection of the engineering systems
• Cabling and connection of the field equipment
• Handing over to the commissioning
6) Commissioning
The commissioning includes system commissioning, cold commissioning and hot
commissioning according to the detailed
• System Commissioning
System commissioning consists of the setting up of the delivered system components.
• Cold Commissioning
During the cold commissioning all process components, connected to the DCS will be set up
for remote operation on drive control level via the operator stations. For this a non-recurring
test of all measurement and control circuits will be executed.
• Hot commissioning and optimization
Precondition for the hot commissioning is the readiness of the mechanical process systems to
dispose their different operation conditions. All tests will be executed on basis of the approved
documentation of the basic engineering. During startup and shut-down procedures, typical
operation and disturbance conditions as well as load variations the function of SCADA will be
verified.
7) Training
Training for Employer’s operator will be conducted by the Contractor’s engineer either during
commissioning or test run (process proving) period, depending on the actual situation and
Employer’s demand.
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Method Statement
PRE-COMMISSIONING AND COMMISSIONING
Pre-commissioning
As soon as the construction work has been mechanically completed, waste water, utilities
and chemicals required for the pre-commissioning are supplied to the plant site.
Pre-commissioning is a preparation work necessary to enter into the following

commissioning of the plant and generally include the final cleaning of the plant, check and
rectification of motor revolution direction, inspection of the functioning of each equipment
and machine, instrument adjustment and calibration, water circulation operation etc.
Commissioning
After the pre-commissioning is completed, the plant is ready for commissioning and is
regarded that the Mechanical Completion has affected. Readiness of the plant for
commissioning shall be confirmed by the Contractor under the consultation with the
Employer.
Commissioning of the plant shall be conducted according to the manner and schedule that
will be submitted to and agreed by the Employer before commissioning.
Commissioning engineers shall be dispatched to plant site from the Contractor. The
Employer shall also assign his operators, maintenance crew and supervisors and position
them to working shift for the plant commissioning.
The following will be conducted during the commissioning.

• Final adjustment of equipment, machines, electrical and instrument equipment
• Warming up operation of the plant and each system
• Rectification and/or modification of the plant facility in necessary
Following the confirmation of the above, each machine shall be tested individually by the 24
hour running test at the presence of Employer’s engineer to check the following.
• Functioning of equipment and machinery
• No fluid leak
• Bearing temperature
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Method Statement
• Vibration and noise

• Availability for continuous operation of the plant
Test run
Immediately after the plant is confirmed by the Employer and the Contractor to be
available for the continuous and normal operation, test run of the plant will be
conducted at the presence of the Employer’s engineers for a minimum period of 30
days to check and confirm the plant performances as guaranteed by the Contractor.
Test run manners and procedures as well as acceptance criteria shall be mutually
agreed by the Contractor and the Employer beforehand.
As soon as the plant performances have been confirmed as a result of the test run, the
acceptance certificate shall be issued by the Employer for the successful completion
and acceptance of the plant.
TRAINING OF OPERATOR’S AND MAINTENANCE CREW
Training for Employer’s operator will be conducted by the Contractor’s engineer either
during commissioning or test run (process proving) period, depending on the actual
situation and Employer’s demand. This is to train and educate the operator in proper
operation and maintenance the moment the project is turn-over to the end user.
10.1.7. Pre-commissioning and Trial Operation (Performance Test)
1) Pre-commissioning
As soon as the construction work has been mechanically completed, waste water, utilities
and chemicals required for the pre-commissioning are supplied to the plant site.
Pre-commissioning is a preparation work necessary to enter into the following

commissioning of the plant and generally include the final cleaning of the plant, check and
rectification of motor revolution direction, inspection of the functioning of each equipment
and machine, instrument adjustment and calibration, water circulation operation etc.
2) Trial Operation (Performance Test)

After the pre-commissioning is completed, the plant is ready for trial operation
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Method Statement
(performance test) and is regarded that the Time for Completion has reached.
Readiness of the plant for trial operation shall be confirmed by the Contractor under the
consultation with the Employer and the Engineer.
Trial Operation of the plant shall be conducted according to the manner and schedule that
will be submitted to and agreed by the Employer before operation. Operation engineers
shall be dispatched to plant site from the Contractor. The Contractor shall also assign his
operators, maintenance crew and supervisors and position them to working shift for the
plant operation.
The following will be conducted during the Trial Operation.

a.) Final adjustment of equipment, machines, electrical and instrument equipment
b.) Warming up operation of the plant and each system
c.) Rectification and/or modification of the plant facility in necessary
Following the confirmation of the above, each machine shall be tested individually by the
24 hour running test at the presence of Employer’s engineer to check the following:
a.) Functioning of equipment and machinery
b.) No fluid leak
c.) Bearing temperature
d.) Vibration and noise
e.) Availability for continuous operation of the plant
3) Performance Test
During the Trial Operation, the Contractor willconduct the Performance Test to ascertain
whether the Facilities attain the functional guarantee considering:
a.) Wastewater Flow
b.) Influent Quality (BOD, SS, T-N, T-P)
c.) Effluent Quality (BOD, SS, T-N, T-P)
d.) Maximum Moisture Content of Dewatered Sludge
e.) Air Emissions Limits
The Contractor assumes that the functional guarantees have been achieved during the
trial operation period. The Contractor will ask third parties of analysis to analyze the
functional guarantee items.
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Method Statement
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Method Statement
10.2. Pipeline Works

The pipeline works is subdivided in four (4) major scopes of works, as for:
a. WWTP Pipeline Works – Yard Piping and Channels, Tanks Draining Pipelines and Tanks
Under Drain Pipelines;
b. Influent and Effluent Lines – Force Main (Influent) Pipeline from MPS to WWTP and Gravity
Effluent Line from WWTP to the Outfall Structure
c. MPS Pipeline Works – Inlet Pipeline to MPS and Overflow Pipeline from MPS to its Outfall
Structure; and
d. Potable Water Supply Pipelines – for WWTP including Fire Water Pipeline, for MPS, and
SDB.
This method statement for the pipeline works methodology covers all requirements of trench
excavation, excavation protection works, rock excavation, pipe jacking system for roads and
railway crossing, excavation in the vicinity of existing utility services, pipe laying procedures,
pipe laying in the existing service duct of bridge, pipeline supports, backfilling, removal of
temporary supports and reinstatement work.
A preliminary study of the work execution shall be conducted to understand existing conditions of
the work area. Surveys will be conducted to establish reference levels, pipeline profile, and data
of existing utility services – Telephone, Electricity and Water/Sewer.
A joint inspection along the pipe route shall be coordinated with the following authorities prior to
start of work:
a. NWSDB
b. Road/Provincial Road Development Authority
c. Sri Lanka Telecom
d. Ceylon Electricity Board
e. Sri Lanka Railways
f. Sri Lanka Police
g. Agriculture Department
h. Institutions/Residents in the Vicinity
i. And other Local Authorities
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Method Statement
Before the start of pipe laying and construction works, particularly in the main road, a Public
Notice Board will be set up indicating date of commencement and expected date of completion
of works.
Setting-Out Works
Setting-out or ground marking works shall be done by a competent person with appropriate
survey equipment. Based on approved construction drawings, correct coordinates and levels
shall be validated referring to the survey bench marks established along the pipe route.
After completing this pipeline tracing, trial or test pits investigations and other sub-surface
studies shall be carried out to assess existing conditions. Final setting-out work will be done as
approved by the Engineer.
Method of working for Pipeline Works in this project will be as follows:
10.2.1. General Notes
(1) Test pits will be conducted at proposed pipe route especially at each street intersection to
determine possible obstruction.
(2) Test pit volume = L x W x depth (invert elevation of proposed line)
(3) Provision of safety requirements such asinformation boards, barricades, safety cones,
warning signals, and lighting facilities of work areas during night time.
(4) Traffic management and control such as stationing of traffic aides will be provided. In the
event of traffic disturbance such as road closure, prior approval of the road maintenance
authority and police department shall be taken.
(5) No open excavation will be left at the end of each working day, if not possible, provision of
steel plates.
(6) All waste excavated materials will be disposed outright at approve disposal areas.
(7) Temporary restoration work will be done. Permanent restoration will only commence after all
the required tests (for Force Main – Pressure Line Test and for Gravity Lines - Infiltration/
Exfiltration Test and Ball Mirror Test) have been satisfactory conducted.
(8) Construction of manholes, where required, will start as soon as pipe laying reaches each
proposed locations.
(9) Manholes will also be tested for Infiltration and Exfiltration Tests.
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Method Statement
(10) Other than soil materials for backfilling, all materials shall be stored as per manufacturers’
recommendation and in a suitable stock yards such that HDPE pipes shall be protected from
direct sunlight, pipes shall be supported with wooden blocks to prevent surface damage, and
loose materials will be placed on crates. Materials will be stored separately in the WWTP
Area, MPS Area and SDB Area. The storage shall be divided into sections such that any
pipe type and material class will be stored in its particular section for easy identification and
retrieval when needed.
(11) Particular attention will be taken on the handling of all materials as for delivery, storage and
transport. Use of appropriate equipment is necessary. Materials shall be suitably covered
and properly supported.
(12) Suitable equipment shall be prepared for the implementation of work. As a minimum, a set of
survey instruments, crane and lifting devices, excavators, delivery trucks and trailers, dump
trucks, water pumps, power generator sets, plate and roller-type compacting equipment, and
other tools will be generally provided.
10.2.2. Pipe Laying Standards
(1) Cutting of pavement (where required) after determination of pipe route based on the test pit
results.
Asphalt or pavement cutter shall be used to cut the pavement surface.
Trench minimum width as required in the Standard Trench Excavations provided in the Bid
Drawings KCWMP/G/C/TS/ 01 and 02.
(2) Breaking of pavement. Use of backhoe breakers
(3) Trench excavation shall be carried out using mechanical excavators such backhoes or
mini-backhoes or manually depending on the site condition of the excavation line.
Trench protection, use of trench box or sheet piles depending on trench depths
Pipe Cover shall be 900mm unless otherwise specifically decided. Trench depths are
dependent on the pipe material, pipe diameter and existing ground condition.
(4) Manual trimming to grade.
(5) Checking of elevation.
(6) Putting bedding material (granular material, minimum 100mm thick).
(8) Installing Pipe Supports (where required)
(9) Pipe laying
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Method Statement
(11) Sand filling surrounding pipe (up to designed pipe cover)

(12) Compaction by water jetting
(13) Placing and Compaction of backfill materials by water jetting.
Placing of Warning Tape (marked: CAUTION – SEWERLINE BELOW) at about 300mm from
the Sand Pipe Surround
(14) Removal of Trench Supports
(15) Placing of Temporary Restoration Material
(16) Reinstatement Work or Pipeline Covering, as required.
For Asphalt & Tarred Carriageway / Hard Shoulders, pipeline cover shall be 200mm thick
aggregate base course at 100% compaction, prime coat with CSS 1 @ 1 liter/square meter,
tack coat with CSS 1 @ 0.5 liter/square meter, and a 50mm thick asphalt wearing course.
And for Earth Shoulders, pipeline cover shall be a 150mm thick layer of Shoulder Material at
100% compaction.
10.2.3. Manhole Standards
(1) Cutting of pavement.

(2) Breaking of pavement.
(3) Trench excavation/ Trench protection, sheet piles.
(4) Manual Trimming to grade.
(5) Check elevation.
(6) Putting gravel bedding.
(8) Concrete pouring (Lean Concrete)
(10) Reinforcing bars installation, bottom slab and wall.
(11) Formworks installation, bottom slab and starter wall at about 500mm high.
(12) Installation of Ladder rungs.
(13) Concrete pouring, bottom slab and starter wall.
(14) Concrete curing and forms removal.
(15) Formworks installation Wall.
(16) Concrete pouring wall.
(18) Formworks installation, wall (to grade).
(19) Installation of ladder rungs.
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Method Statement
(20) Concrete pouring, wall (to grade).

(22) Reinforcing bars, installation (to slab).
(23) Formworks installation (top slab).
(24) Installation of manhole frame and cover.
(25) Concrete pouring, top slab.
(26) Concrete curing/ forms removal.
(27) Backfilling (fine sand) to grade, top of pavement.
(28) Removal of Trench Protection.
10.2.4. Other Pipeline Works Requirements
(1) Dewatering Operation

At all times, hand-pump equipment or submersible pumps (gasoline or electric powered) in
good working conditions shall be made available during excavation work. Ground water level
has to be checked prior to start of excavation.
Prior to commencing the pipe laying, it is necessary to dewater the pipe trench for which the
pipe will be laid. Well point system with filter shall be provided.
Sump pumping at the end of the trench is not recommended considering instability of the
excavation wall/formation arises.
Surface runoff will be controlled by diverting surface runoff water by dike or temporary canal
system to prevent entry or collection of water to the excavation pit.
Dewatering shall be used until the final backfilling has been laid and compacted as required.
(2) Excavation Protection by Shoring or Use of Trench Box

Deep excavations (more than 2.00 meters) or excavation below ground water table or
excavation into weak soil condition; trench must be protected suitably protected. The use of
shoring such as timbering or sheeting or the use of trench boxes is a must to provide a safe
working condition.
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Method Statement
Depending on the situation, the use of trench protection has to be strictly studied and
implemented to address risk of excavation wall collapse. In some adversely difficult
situations, such as the 4-meter trench excavation for the Gravity Effluent Line or the Entry
and Exit Pits for the Pipe Jacking System, driving vertical supports such as H-beams at
designed intervals or using sheet piles if so needed, will be required. A further study of the
ground condition prior to this work section implementation will be conducted to assess the
required excavation protection.
(3) Pipe Cleaning before Laying (particularly for D.I. Pipes to be used for Force Main)
D.I. Pipe cutting to its required length shall be done using the appropriate pipe cutter.
Cutting edge of the pipe will be tapered by using grinders.
Placing the D.I. Pipe into the trench shall be by use of suitable lifting equipment such as a
Crane Boom Truck. The spigot socket is cleaned and shaped to ensure that there is no any
sharpen edge. The rubber ring should be wiped, cleaned and placed in the groove of the
socket. A thin film of lubricant is to be applied to the inside surface of the rubber ring which
will be in contact with the entering spigot.
The outside of the pipe spigot is cleaned and the portion is filed until rough edges is
removed and will also be applied a thin film of lubricant.
To assemble the joints, use of either a ratchet or excavator bucket is provided to suit site
condition. In laying the force mains, according to the final completed pipe profile, a washout
or blow-off valve has to be provided to the lowest point and an air-relief valve will be
installed in the highest point. Depending on the pipeline profile, in some cases several
blow-off valve and air-relief valve will be required.
In case of flanged-joint, it should be coated including all bolts and nuts with Denso paste
and primer, Denso mastic, Denso tape and PVC or Polyethylene outer wrapping.
And accordingly, concrete thrust blocks shall be provided at all pipe bends against thrust
force.
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Method Statement
(4) Pipe Jacking System

Considering the pipe route of Force Main from the Main Pump Station (MPS) to the
receiving preliminary process tank in the Wastewater Treatment Plant (WWTP), it will pass
through a railway/road (1 location) and roads (2 locations). Based on the initial surveys
conducted, the original pipe route along the William Gopallawa Mawatha Road and
Gannoruwa Road is not feasible due to constraints of limited work areas and a major traffic
disturbance. Assessing a feasible route relocation plant to prevent a major disturbance on
this railway and major roads traffic, an alternative pipe route is proposed with a
micro-tunneling method or pipe jacking system to be implemented.
From the MPS, the Force Main will cross the William Gopallawa Mawatha Road. It is
proposed that the alternative pipe route be placed inside the Getambe Ground, an open
grounds parallel to the railway/road. The road crossing will have to be done using a pipe
jacking system.
The pipe route will then cross the Peradeniya Road near the Getambe Roundabout for
which another pipe jacking system will be used. From this point, it will cross the Mahewali
River along the service duct at the right side of the Gannoruwa Bridge.
And it will then cross the Gannoruwa Road by pipe jacking system entering the service road
going to the WWTP site.
Pipe Jacking is a specialist tunneling method used to avoid a major surface disruption on
the traffic of the railway and roads to be crossed by the pipe laying.
Pipe jacking system is a general technique of the installation of pipes with a tunneling shield
or pipe casing in front and the pipes are jacked from a jacking entry pit to a receiving pit.
Excavation is carried out in a shield forward of the leading pipe as the pipeline is pushed
out of the jacking pit and the process repeated. Excavation can be by hand or machine,
depending upon the conditions. But nevertheless, safety will be of utmost concern since
this involves working condition on a very much confined space.
Soil investigation of the jacking and its pits locations is a major factor. It influences the
excavation method of the entry and receiving pits, the required temporary works, jacking
length, pipe casing design and, if so needed, ground stabilization.
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Method Statement
Differing soil profile needs to be assessed as appropriate. Water table has to be checked.
The Force Main to be constructed is to use a 600mm diameter D. I. Pipe. Preliminary

design requires a 900mm diameter steel pipe casing has to be provided. Steering the pipe
casing requires the best installation practice from the setup of pipe casing entry, pipe
alignment tolerances – 75mm for line and 50mm for level, and regular alignment checks.
Records have to be prepared on a regular basis. Data monitoring is a must on main survey
checks, line and level, pipe casing position, pipe rolling, main jacking load, inter-jack load,
casing load, total load, and surface checks.
(5) Pressure Testing of Force Main

For the pipeline work of this project, the construction of Force Main is one of the critical
aspects. It involves laying 1,032 meters of 600mm diameter D.I. pipes crossing main roads
and the Mahaweli River along the Gannoruwa Bridge. For this purpose, three (3) locations
of pipe jacking system have to be setup.
The pipe length to be pressure tested will be based on the locations of the jacking points in
segments such as (i) MPS to the first jacking receiving pit inside the Getambe Ground, (ii)
from the first jacking receiving pit to the second jacking receiving across the Peradeniya
Road, (iii) from the second jacking receiving pit to the third jacking receiving pit across the
Gannoruwa Road, and (iv) from the third jacking receiving pit to the inlet tank of the
preliminary process tank in the WWTP. After all the interconnections have been completed,
a final pressure testing of the total 1,032-meter line shall be tested.
The both ends of the segment to be tested will be blocked and supported by a concrete
thrust blocks. The lowest end of the segment shall be prepared for water filling while the
other end will be prepared for air releasing. Water to be used is clean, potable water from a
natural water source and to be transported to site using water tankers.
The water should be slowly filled at the lowest end using booster pump until a 10-bar
pressure can be attained. This pressure shall be kept for 24 hours and regularly checked
for pressure drop. A pressure drop signals a leakage on the tested line. The minimum
allowable leakage is calculated using the requirements and formula to be specified by the
Engineer.
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Method Statement
Only after the successful completion the pressure testing that the final reinstatement of the
ground surface shall be started.
(6) Rock Breaking/Excavation
Whenever necessary, rock breaking/excavation will be done using heavy earthmoving

equipment and latest technologies on hard rock breaking/excavation without blasting. This
rock breaking/excavation methodology will employ applicable procedures, as for:
1) Rock breaking using rock splitting method by Hydraulic Rock Splitters;

2) Rock sawing using Diamond Wire Saw Equipment;
3) Rock cracking using Chemical Expansion Mortar to crack the rock, and breaking it using
Hydraulic Rock Breakers;
4) Rock breaking using Excavator mounted with Heavy Hydraulic Rock Breakers;
5) Rock breaking by Compressors with Pneumatic Jackhammers; and
6) Rock breaking using manual chiseling and wedging method.
10.3. Civil and Building Works
10.3.1. Scope of Work
The Project comprises of three (3) major areas for the Wastewater Treatment Plant (WWTP) and
its Facilities, Main Pump Station (MPS) Building and Sludge Drying Bed (SDB) Facility, and
seven (7) locations for the New Operations Building and several Staff Quarters.
WWTP and its Facilities includes Preliminary Process Building (Screen and Grit Chamber),
Oxidation Ditches (4 units), Sedimentation Tanks (4 units), Disinfection Building and its
Disinfection Tank, Sludge Pump Building, Sludge Treatment Building including the Electrical and
Power Generator Room, Administration and Control/Monitoring Building, Work Shop and
Garage, and other facilities such as Flow Meter Chambers, CEB Substation, and Guard Post.
WWTP covers about 26,000 square meters of development providing essential facilities and
services for its operation. This includes clearing and grubbing the total area, land improvements,
slope protections along Mahaweli River, fences, noise barriers and gate, road networks, and
other access requirements.
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Method Statement
It will also be provided with Effluent Disposal System of sewer pipeline crossing the Gannoruwa
Road to the Discharge Structure or Effluent Outfall to be constructed downstream.
MPS is to be located also in Getambe along the William Gopallawa Mawatha Road on an 880
square meter lot. The 3-level building will house the intake structure with coarse and fine
screenings, grit chambers and the wet well pump pit at about 8 meters underground, the Staff
Office, Tool Room and Toilets, Grit Classifier Facility and Generator Room at the first level, and
the Electrical Room and Deodorization Room at the second level.
The MPS Facility will also be provided with its Loading Bay Area, its own Sub-Station, receiving
manholes for the Inflow Pipe, and as well as an Overflow Pipe directed to Discharge Structure in
the Meda Ela.
SDB is to be located inside the Tekawatta Mixed Garden Municipal Property adjacent to the
Mahaweli River. Covering about 4,100 square meters of land, SDB Facility includes 5 units of
sludge drying bed buildings with its corresponding land developments of paved road network,
fence and gate, storm drainage system connected to a discharge facility having an outlet in the
Mahaweli River, and a Staff Office Building.
The required Operations Building and Staff Quarters are:

i. Director Quarters and Manager Quarters in Rajapihilla Mawatha;
ii. Engineers Quarters in Tissarama Mawatha;
iii. 3-story Operations Building and Officer In-Charge Quarters to be located in the part of KMC
Land at Getambe;
iv. Technical Officer Quarters in Reservoir Road – 01;
v. Technical Officer Quarters in Reservoir Road – 02;
vi. Technical Officers and Electricians/Mechanics Quarters at Dangle Children Park; and
vii. Operators Quarters in Dangolla Ayurveda.
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Method Statement
10.3.2. General Construction Requirements
1) Demolition of Existing Structures

Any demolition of existing structures, which are obstructing the construction of the proposed
sewer network, shall involve provision of temporary and alternative arrangements for existing
roads and services. The demolition site will be barricaded to prevent unauthorized personnel
from entering the site. Signs & warning tape will be installed to warn traffic.
Where necessary, the demolition contractor will be requested to prepare a demolition plan.
Any such demolition plan shall be submitted to the engineer and all those affected or
concerned shall be kept informed about the activity.
Before commencing demolition work, adequate supports to existing super of sub-structures

shall be provided according to specifications. The demolition shall be carried out with a
minimum of disturbance to those parts of any existing structures. In case of sub-structures,
necessary earth supports such as sheet piles shall be driven in, to the required depth.
Heavy machinery will not be used for demolition unless absolutely necessary. The
development of defects on existing structures will be monitored during demolition. Small
machinery and an appropriate technique, as approved by the Engineer, will be used and
methods that control pollution and environment impacts will be adopted.
Remaining demolition materials will be transported off-site, to a designated dumping site. The
Engineer’s assistance is required in arranging suitable dumping sites.
2) Site Clearing and Grubbing

Once approval has been given, for the preliminary setting out of the structures, the site
clearance will start. This work includes removal of trees, vegetation, topsoil and provision of
access road to the site. Clearing will be carried out according to details on drawings. Top soil
and suitable material generated during site clearance, will be stored on site, for landscaping
and embankment work.
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Method Statement
3) Earthworks –Common Excavation, Rock Excavation, Cutting and Filling

Earthworks will be carried out using standard earth moving equipment such as excavators,
dozers, dump trucks, loaders and vibrating rollers. Excavation commences soon after
determination of the formation level for the structure.
Minimal disturbance to existing services and structures, utilization of efficient and

environmentally friendly construction equipment make for trouble-free earthworks.
The excavation will be prepared immediately afterwards, by compacting. Where necessary

base course of selected graded aggregate or recycle material will be placed in uniform layers
of thickness 250mm and compacted.
Where appropriate, the contractor may opt for thrust boring, to make road crossings. This
system could reduce open out excavation across roads. Trial pits and detectors shall be used
to locate existing services. For open cut trench excavations in self-supporting ground, the
mechanical excavators or backhoe machines will be used in open cut. All excavations deeper
than 1.5m will have suitable support, whether it would be timber planking, drag-boxes,
sheet-piles or steel shoring.
With extreme precaution the free split type control blasting technology [delay detonating] shall
be utilized for rock excavations. Handling of explosives will be supervised by a blasting
foreman with a minimum 10 years of experience in controlled blasting. Percussion type
silencer fitted drilling. Per blast advance is limited to 1.5m and before blasting the rock surface
shall be fully covered with a suitable bunker, such as tires connected with chain link mesh.
The relevant blasting permits, storage of blasting materials, transport to site and loading shall
all be in accordance with the blasting standards and the regulations of the GOSL. Detailed
arrangements will be notified later.
Granular material bedding and backfilling of trenches with imported materials shall be in
accordance with the specifications and details shown on the drawings. A combination of
pneumatic compactors, plate compactors and drum rollers will be used for compaction, in
layers not exceeding 200mm.
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Method Statement
4) Foundation Work
The basic concept for the foundation work is taken from the recommendations given in the
geotechnical investigation report, provided with tender documents. Taking into account the
geotechnical investigation carried out on the proposed sites and on the assumption that sound
rock could be encountered at average depth of 5m below ground, no piling is required. A
granular material sub-base cushion will be placed and compacted below the foundation.
Ground water is anticipated at 1 – 2m below and lowering the water level under foundation will
be carried out with drainage pipe and a pump sump system or well points if necessary. The
drain pipes will collect ground water and take it to a pumping shaft outside the structure.
In cases where the remaining ground water affects the foundation works, perforated drain pipe
in near horizontal filter layer below the base, will be installed.
5) Installation of Gravity Sewers

Installation will be in accordance with the technical specifications. The work shall be
programmed, to precede or follow earthwork and structural works, as necessary and practical.
The laying of pipes will proceed in conjunction with the construction of manhole, culvert
crossings, and inspection chambers.
6) New Structures Construction

i. Formwork
In general shuttering panels will be used for connection of walls and through-bolt holes will
be sealed on removal of the shuttering. Shuttering materials and arrangements will comply
with requirements of the Standard Technical Specifications [Section 7.8] of the Contract.
Construction joints will be provided wherever shown on the drawing details.
ii. Concrete Work

During the design stage, the type of concrete and design mixes, including quantities of
cement, aggregates, sand & water will finally be defined. We propose C35A Sulphate-
resistant concrete for all lifting stations and C25 for all other concreting, such as thrust
blocks, pipe supports, inspection chambers, and others.
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Method Statement
The majority of concrete placed will be carried out using mobile concrete pump, crane &
skips, chutes or tremmies. Compacting will be done using concrete vibrating pokers of a
suitable diameter. Additional equipment for successful placement and compaction of
concrete will be sourced as necessary. Curing will be carried out using water and the
structures will be covered in jute/hessian sacking or similar, keeping the fresh concrete
wet. Concrete testing will be in accordance with the specifications.
Some per-cast item such as manhole rings, cover slabs etc.., will be sourced from locally
reputed manufacturers, while a small per-cast yard will also be established adjacent to the
batching plant site, for all small and special types of per-cast items. (Concrete interceptor
units for house connections, being one such special item)
The on-site batching plant will manufacture all the concrete required for the sewerage
project.
iii. Reinforcement
Reinforcement will be stored in accordance with the manufacturer’s recommendations and
shall comply with the standard technical specifications. Correct installation and layout of
reinforcement shall be maintained by the use of cement mortar spacer blocks and/or
plastic spacers.
iv. Site Development Works and Landscaping

The Site Development Plan with its landscape drawings shall be prepared and submitted
for approval during construction stage. The extent of this work shall cover the slope
protection walls, security fence and gate, road network,storm drainage system and
perimeter lighting system shall. Landscape designs including the type of vegetation to be
planted and turfing to be carried out will be decided at a later stage.
10.3.3. Specific Construction – Oxidation Ditch
The Oxidation Ditch is the biggest structure in this Wastewater Treatment Plant Project. For
this project, it requires four (4) units of oxidation ditches with each having internal
measurements of 76 meters in length, 12.30 meters in width and with a depth of 5.70 meters.
With its huge volume of construction work, this can be considered as one of the critical
scopes of the project.
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Method Statement
Based on the Hydraulic Profile, the wastewater will be coming out from outlet chamber of the
Distribution Chamber at a Mean Water Level (MWL) +472.994 with a high of HWL +473.291
and a low of LWL +472.900. In the Oxidation Ditch, the water level will be maintained at a
Mean Water Level (MWL) 472.972 with a high of HWL +473.057 and a low of LWL +472.900.
These level have been referenced to the design Finish Ground Level of +473.00 based on
the maximum protection level (to protect the facilities from flood) of +472.40 MSL.
Considering the projected depth of excavation of about 5 meters and the existing soil
conditions to be generally soft soil, extreme care must be taken in the excavation works with
necessary protections and suitable work sequence.
1) Site Clearing
Appropriate equipment such as excavators will be used for clearing the site area. Big
trees will be cut manually, after receiving required approvals. Cut trees will be handed
over to relevant authorities as per the request of Water Board. Temporary access road
will be constructed to facilitate to take the machineries inside the site. All rubbished and
top soil will be removed from site to the pre-approved designated dumping yard.
2) Setting Out - Markings and Layout

After removing top soil, setting out will be done by an Engineering Assistant supervised
by Engineer according to the setting out drawings. All the setting out works will be
checked by our experienced Site Engineer and finally approval will be obtained from the
NWSDB.
3) Excavation Works
Excavations will be done using mechanical excavators.
Excavated material which will not be suitable for back filling works will be removed from
site. Dump trucks and tractors will be used to transport the unsuitable materials to
dumping areas.
Minor excavation such as trench excavation and vertical slope excavations shall be done
manually. All the excavations shall be done according to the lines and levels indicated in
drawings. Special attention will be paid to avoid the over excavation.
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Method Statement
4) Screed Concrete
Grade – 15 concrete that shall be produced and transported to site by truck mixers and
placed as screed concrete.
5) Reinforcing Steel Bars Fixing and Base Concreting

Reinforcing steel bars will be cut and bent according to bar bending schedules and will be
transported to site by crane trucks. Reinforcing steel bars bending and fixing will be
done by skilled workers (steel men) using bar – benders under supervision of
experienced Bar Bending Foreman, according to the drawings.
Reinforcements will be placed and tied as per the reinforcing steel bars drawings.
Cover blocks will be placed to maintain the required cover and necessary box outs will be
kept as detailed in drawing to place pipes etc. After receiving approval for reinforcing
steel bars fixing, concreting will be commenced.
Grade – 35A ready mix concrete produced at batching plant will be used for all the
concreting works. Skilled workers will place the concrete by the help of skip bucket hang
on crane or alternatively pumped in place using adequate concrete pumping equipment.
Concrete will be handled in such a way to avoid segregation of material inside the
concrete during transporting, placing and compacting.
Construction joints will be cleaned for loose particles and dust and approved bonding
agent will be applied.
6) Reinforced Concrete Wall Concreting

Grade – 35 A concrete will be used for wall concreting. 300mm high kicker wall will be
formed to start the walls. All the constructions joints will be green cut. British Standard
guidelines shall be applied for green cutting. The horizontal joint surfaces shall be
roughened without damaging the coarse aggregate particles by spraying the joint
surfaces about 02h to 04hr after the concrete is placed with a fine spray of water. An
approved bonding agent will be applied on joints before starting concrete. Maximum
height of concreting is 2m and wall will be concreted in 3 lifts.
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Method Statement
7) Man Power
a.) Site Engineer - 01

b.) Engineering Assistant - 01
c.) Technical Officer - 01
d.) Supervisors - 02
e.) Crane Operator - 01
f.) Bar Bending Foreman - 02
g.) Carpentry Foreman - 02
h.) Concrete Foreman - 02
i.) Skilled Workers - 12
j.) Unskilled Workers or Labors - 20
8) Machine and Equipment
a.) Ready Mix Concrete Truck - 05 Nos.

b.) Mobile Concrete Pump - 01 No.
c.) Concrete Mixer, 5m3 Capacity - 02 Nos.
d.) Electric Generator Set - 02 Nos.
e.) Air Compressor - 01 No.
f.) Plasma Cutting Tools - 02 Nos.
g.) Concrete Vibrators - 08 Nos.
h.) Power Saw - 01 No.
i.) Hand Tools
9) Quality Control
(1) Measuring Instruments - Measuring instruments will be calibrated periodically.
(2) Construction Materials - All the construction materials will be unloaded to site
after checking by our staff.
(3) Gradation - Gradation of construction material will be checked periodically.
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Method Statement
(4) Concrete
Slump and temperature of each truck load will be checked before placing. Test
cubes will be cast as per the requirements of specifications. Skip buckets or
pumping will be used to place concrete and it will avoid segregation of material
inside the concrete. Special attention will be paid not to create cold joints
during concreting. Concrete vibrators will be used to compact the concrete
and skilled operators will operate vibrators.
Curing will be done for at least 7 days after placing the concrete. Continuously
wetted gunny bags will be used for curing. Soundness of all the machines
and equipment will be checked by Mechanical Foreman before starting
concreting. All the workers will be instructed to maintain the quality.
Calibration of instruments will be carried out as bellow.

i. Leveling Instrument – Once a year or if any error is indicated.
ii. Theodolite – Once a year.
iii. Weighing Machines – Once a year.
iv. Test Equipment – Once a year.
v. Batching Plant.
Weighing – Twice a year.
Water – Before starting major concrete works.
vi. Gradation will be checked.
When visual difference of material is observed.
If the Jaw’s in crusher machine is adjusted or replaced.
For every 100 cubes of metal production.
10) Site Safety

All the workers will be required to wear their standard Personal Protection Equipment or
PPE such as helmets and safety boots before entering work site. Notice boards will be
kept in safety-hazard areas. Only authorized skilled operators will operate machines and
equipment. No visitors are allowed to enter the work site without the approval from site
Engineer. Well-equipped first aid box complete will all necessities will be always kept at
site for emergency use.
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Method Statement
10.3.4. Specific Construction – Sedimentation Tank
Another critical scope of the project is the Sedimentation Tank. This circular structure is designed
to be of 23 meters diameter and tank depth of 7.20 meters at its center.
To be constructed adjacent to the Oxidation Ditches, the excavation could be as much as 8 meters.
And with its bottom slab designed to be sloping to its center, construction has to be strictly checked
considering required levels.
The wastewater supply pipe from the oxidation ditch will be entering to its bottom. Water level is to
be maintaining a Mean Water Level (MWL) at +472.469 with a high level of HWL +472.481 and a
low level of LWL +472.450.
1) Screed Concreting and Mass Concreting in Slopes

After excavating and backfilling to required depth, Grade – 15 concrete, which will be
produced at the batching plant will be laid in 50mm layers by skilled workers. For mass
concrete filling sections, rigid shuttering will be made before placing concrete. Concrete
will be produced by batching plant and will be placed within 45 minutes after mixing.
2) Steel Reinforcement
After receiving the approvals for the bar schedules or shop drawings, bar bending will be
started according to approved bar schedules. Polyethylene sheet of 6 mils of gauge 600
will be laid over the screed concrete as damp proofer. Fixing of reinforcements will be
commenced according to the reinforcing steel bar drawings by skilled workers under the
supervision of a Bar Bending Foreman and Supervisor.
3) Base Concreting
Grade 35 A ready mix concrete, which will be produced at the batching plant will be used
for base concreting. Two truck mixers will be used for transporting concrete and ‘U’
shaped chutes and skip buckets hanged on cranes or alternatively adequate concrete
pumping equipment will be used for placing of concrete.
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Method Statement
Before mixing of concrete starts, Mechanical Foreman will inspect the soundness of
batching plant, track mixers and vibrators. Batching Plant Supervisor will check the
moisture content and other parameters of aggregates.
Carpentry Foreman will check the formwork while Bar Bending Foreman checks
reinforcement. All the equipment that will be used to transport and place concrete will be
cleaned thoroughly.
Slump and temperature of each load of Ready Mix Concrete Truck load will be checked
before placing and test cubes will be cast as per the requirement of the Water Board and
the Consultant.
Base slab of Sedimentation Tank will be divided into an appropriate number of parts for
concreting.
All vertical walls of the tank will be cast monolithically with base slab.
Thereafter, concreting will be done as group wise for, say six individual days. Special
care will be taken to avoid segregation of aggregates during placing and concrete will be
discharged completely from mixer and mixer will be cleaned before it is recharged. The
elapsed time between mixing and placing will be kept to a minimum and concreting will be
done methodically to avoid the cold joints.
Compaction of concrete will be done by using Concrete Vibrators. Experienced operators

will operate vibrators under supervision of a technical staff.
In construction joints, dirt, dust and loose particle of previously done concrete will be
removed by using chisels, drills and compressor. Approved bonding agent will be
applied on construction joints before starting the next portion of the base.
If the temperature of concrete increases above 32C0 while pouring, then iced water will be
used for concrete mixing and aggregate stocks will be kept in cover to prevent the
absorption of heat.
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Method Statement
4) Curing of Base Slab

Continuously wetted gunny bags will be laid over the base slab and curing will be done
for at least 07 days, after placing the concrete.
5) Reinforced Concrete Wall Concreting

Reinforcement will be fixed according to drawings. Then 100 mm high kicker will be
concreted and formwork fixing will be started after applying thin layer of mould oil.
Adequate number of jacks and props will be provided to avoid bending or twisting the
formwork. Formwork will be manufactured by skilled workers using double coated fly
woods, 2”x2”, 3”x2” Timber, GI pipes, form ties and U – jacks. Adjustable jacks will be
used for making form work. Plastic cones and separators will be used for maintaining
thickness of walls. The maximum height of concreting will be limited to 2m and concreting
will be completed in 3 lifts. Before form materials are reused, all surfaces that have been
in contact with concrete will be cleaned. All damaged places will be repaired and all
projecting nails will be removed. Thereafter, a thin film of mould oil will be applied.
When concreting the walls and center column, openings will be kept where the locations
of pipes are indicated in drawings. These openings will be covered by approved non
–shrink grout after placing pipes.
Construction joints of previous concrete will be cleaned and loose concrete particles will
be removed. Approved bonding agent will be applied before concreting next lift. Curing
will be done by covering continuous wetted gunny bags on walls and columns.
6) Manpower or Personnel Schedule
a. Project Engineer - 01
b. Engineering Assistant - 01
c. Concrete Foreman - 01
d. Bar Bending Foreman - 01
e. Carpentry Foreman - 01
f. Batching Plant Operator - 01
g. Laboratory Technician - 01
h. Equipment Mechanic - 01
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Method Statement
i. Site Electrician - 01
j. Skilled Workers - 04
k. Unskilled Workers/Labors - 14
7) Equipment Schedule
b. Truck Concrete Mixer

5m3 - 02 Nos.
2.5m3 - 01 No.
c. 20 Ton Crane - 01 No.
d. Skid Bucket - 02 Nos.
e. Concrete Vibrators
2” - 02 Nos.
i. ½ “ - 02 Nos.
f. Generator Set 60 KVA - 01 Nos.
10.3.5. Specific Construction – Main Pumping Station
The Main Pumping Station (MPS) will consist of a collection sump and provision for 4 units’ sewer
pumps that will be installed approximately 10meters below the ground level. The facilities required for
the operation of the MPS are overhead crane, coarse screens, fine screens, grit removal facility
including grit classifier and grit pumps, dewatering pumps, access stairs, ventilators, and odor removal
facility that will be designed to suit the requirements.
This structure will be designed for severe exposure conditions and the construction materials will be
selected to ensure durability conditions.
The construction of the MPS is critical considering depth of excavation about 7 meters for which its
rear portion is adjacent to a creek. The required excavation protections will be provided and containing
the perimeter with construction of retaining wall will be made priority.
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Method Statement
1) Method of Excavation
a.) The first step is to secure the rear portion adjacent to the creek by providing
excavation protection. Dewatering operation all through the excavation work shall be
commissioned to keep the excavation pit free of water.
b.) Wall excavation protection shall continue simultaneously with the excavation
procedure.
c.) Supports will be secured and a strict monitoring of soil movements around the site
shall be checked.
d.) Using mechanical excavator, the lower portion the pit will be excavated up to bottom of
the base slab. It will followed by manual excavation to trim the pit to its desired level
and dimensions.
e.) Then a screed or lean concrete of 50mm thick is placed at the bottom of the pit.
Dewatering provisions for pumping of water will still continue until the total basement
walls have been raised.
2) Main components of the Structure

The civil structure will consist of following main components
a. Excavation protection wall at the periphery.
b. Excavation protection walls supports.
c. Base concrete slab of approximate 1meter thick at a depth of 7 meters from the
ground level.
d. Separation concrete wall between grit pit and pump pit. This will act as a supporting
beam for the base slab.
e. Separation concrete wall between pump pit and the sewer sump. This will act as a
supporting beam for the base slab.
f. Access stairs and floor slabs as indicated on layout plans.
g. Gantry beam supported on concrete columns staring from capping beam.
h. Zn, Al roof structure on steel trusses.
3) Design concepts for structural members

Generally all the structural members are designed to satisfy the severe exposure
conditions. The concrete material to be used below ground structures are designed to
satisfy the sulphate and chloride content of the ground water. All underground structural
elements are designed for Grade 35A concrete. The design will be carried out in
accordance with the following codes and standards.
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Method Statement
Underground structures : BS 8007 (1987) ; BS 8110 (1995)

Structures Exposed to Sewer : BS 4027/BS 8110 (1985)
Cements : BS 12
Other Structures : BS 8110 (1985)
Steel Structures : BS 5950
General Loading : BS 6399
a. The excavation protection walls are designed to resist the loads due to ground water
and earth pressure as well as the loads acting from the super-structure.
b. The base slab will be designed to resist the vertical loads acting on the base and the
up lift pressures.
c. The cross beams, slabs and ring beams will be designed to withstand the loads
acting on them from secant pile walls and vertical dead and imposed loads as per
BS 6399.
d. The concrete will be grade 35 and grade 35A. Grade 35A concrete will be
produced to suit the specifications given for the concrete, for example, the maximum
cement content will be 400 kg/m 3 and max. Water/Cement ratio will be 0.50. The
slump of the concrete will be set to suit a mix which can be pumped or equal to
180mm.
e. Minimum cover to reinforcement will be 50mm for structures below the ground and
25mm for the members above the ground.
f. The type of steel will be in accordance with BS 4449. High yield steel with
minimum yield strength of 460 N/m2 will be used.
4) Ground and First Floors

Grit classifier, gantry cranes, valve and gate controls, changing and wash rooms and
generator room will be located at the ground floor level. First floor will accommodate
control room and deodorization rooms. The generator area will contain the diesel fuel
storage tank and containment area. Entrance to the valve chamber will be available
through an access hatch in the floor of the control room.
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Method Statement
5) Wet Well
The wet well will be located below ground level and is sized to provide adequate storage of
sewage between pump starts.
Wet well sizes are calculated based on the minimum cycle time of pumps is 10 minutes or
6 starts per hour for peak flow condition. The area of the wet well is sized to adequately
accommodate all the pumps on duty and on standby as per the manufacturer
requirements.
The pumping station is designed to minimize the need for operator entry to confined
spaces. Therefore, gantry cranes are provided to allow convenient removal of pumps
should they require servicing. However, should there be a need to access the wet well,
aluminum ladders located on the ground floor will provide access to the wet well from the
ground level.
In the unlikely event of a total station failure, a by-pass pipeline will direct excess sewage
to a nearby creek to prevent flooding of the pumping station control room and surrounding
residential dwellings. The overflow pipe inlet will be equipped with a check valve and
insect screen and located below the critical basement elevation of surrounding properties.
However, back-up and alarm systems are integrated into the design to minimize the
chance of total failure.
6) Pumps
Wet well Submersible pumps were selected for the pumping station because they require
small installation footprint, no cooling requirement and reduced overall construction costs.
The numbers of duty pumps have been sized to meet a peak flow condition at a total
dynamic head. An additional identical pump (minimum 50% of duty pumps) is to be
made available as standby in the event that one (1) pump fails or is taken out of service.
During normal operating conditions, it is expected that only one or two duty pumps will be
required. During peak flow conditions, other duty pumps will run in parallel to meet peak
flow.
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Method Statement
7) Station Piping
The station piping and force main header will use steel pipes as required by the employee.
Gate valves will be provided to control the flow of sewage from the pumps and check
valves will be used to prevent backflow in each pipe header. Air release valves will also
be installed to remove entrapped air and a surge relief valve will provide adequate
buffering against pressure surges by draining sewage back into the wet well if gauge
pressure exceeds a threshold units.
8) Inlet Screening
A manually cleaned coarse bar screen will be installed at the inlet channel sewer entering
the wet well of pumping station. A portable trash receptacle at grade will be used remove
accumulated solids. The equipment will be fabricated from stainless steel and the bar
spacing will be approximately 50mm dictated by the passage size of the duty pumps.
For Getambe pumping station, 2 manual bar (coarse) screens (50mm), two electrically
driven fine screens (10mm), vortex type grit trap with grit classifier will be installed for each
of the 2 trains of wastewater entering. All the above equipment will be fabricated in
stainless steel.
10.3.6. Specific Construction – Effluent line and Outfall Structure
The Effluent Line will be constructed along the Access Road coming from the treatment plant. It is also
on this road that the Force Main Influent Line will be constructed going to the treatment plant.
Considering this, work programming will be the main concern so as to avoid or limit construction
constraints due to movability and access.
From the treatment plant going to the outfall structure area, level reference will be set up. Since the
effluent line is a gravity line, level is highly critical. A level check during construction is important.
The work involves 825 meters of pipeline. The use of sheet piles for excavation protection is planned.
This is considering that for gravity lines excavation gets deeper as it extends. A micro-tunneling is also
planned crossing the road junction. From Katugastota Road going to the Outfall Structure is a rather
steep slope. A drop manhole is initially designed to address this concern.
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Method Statement
The Outfall Structure will be constructed along the river bank of Mahaweli River. The structure, a
reinforced concrete, will be protected with gabions to its sides to avoid damage and river bank
scouring.
Specific Construction – Access Road
The existing access road to be used during the construction of the treatment is also the same road
where the Force Main Influent Line and Gravity Effluent Line will be constructed. In connection to this
work programming will be the essential aspect for the Access Road construction.
In the General Work Program, the construction of treatment plant will be started ahead of the influent
and effluent pipelines. During this period the maintenance of the Access Road will be observed and
implemented.
After the completion of the pipeline works running through this Access Road, the road will be restored
and improved.
10.3.7. Specific Construction – Sludge Drying Bed Facility
The sludge drying bed facility is to be located in Gohagoda next to the sanitary landfill site. The
construction is planned to provide five (5) sludge drying beds. Dewatered sludge cake from the
treatment plant shall be delivered to this facility by 10-ton dump trucks and will be dried before final
disposal.
Main concern for construction is the access to site due to narrow existing road. Heavy equipment for
site area clearing and leveling will pass here including dump trucks that will be used to dispose of
surplus materials. This access road will be subject for development or widening where necessary and
for maintenance. Site clearing and leveling would be a major scope of work to include a general area
clearing covering more than 4,000.00 square meters and a soil cut and fill for about 6,000.00 cubic
meters of soil.
The facility is designed to accommodate truck movements for easy maneuverability in the unloading of
sludge cakes to the drying beds as well loading of dried sludge for disposal. This internal road network
is to aid in developing a fully functional facility.
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Method Statement
The drying beds shall be a monolithic reinforced concrete slab. Knee walls 1.2m high will be provided
to avoid spillage. A transparent roofing is to be used and with full open sides to promote drying.
Filtrate from these drying beds will be collected to a sump/manhole for which will be emptied using
vacuum tanker to be brought to the treatment plant.
Development works will be providing storm drainage system directed to an outfall in the river bank of
Mahaweli River and perimeter fence and area lighting for security.
10.3.8. Standard Mitigating Measures – Impact of Construction
Potential impacts of construction activities on the environment (construction dust, odor, noise,
sediment and any potential contaminated soil) must be mitigated throughout the implementation period.
The best construction management practices will be followed to minimize the adverse effects on the
surrounding environment. The following controls will be implemented to provide monitoring
throughout the construction phase.
10.3.9. Mitigation Measures before and during Construction
The mitigation measures to prevent environmental degradation due to construction activities will be
adopted as indicated in the following table and the measures identified during the construction will be
adopted. The Construction Environmental Mitigation Plan (CEMP) will be prepared on mobilization to
cover all the aspect for approval of the NWSDB before commencing any of the works.
Prior approval will be necessary for certain work items to be implemented. These procedures will be
agreed upon the initial planning phase of the construction activities.
Such Environmental Aspects and its corresponding Mitigating Measures are as follows:
1) Traffic and Transport

 Construction Traffic Management Plan will be prepared and incorporated into the
Construction Environmental Mitigation Plan (EMP);
 Construction areas to have speed limits regulated at 40km/h;
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Method Statement
 Traffic warning signs and construction speed limits will set around construction areas,
trained personnel will be used to control access to work sites and where lane closures are
required;
 Equipment and Materials storage to occur on existing cleared land or land which will be
occupied by proposed works and which will therefore be cleared to permit construction.
This is to include construction of Wastewater Treatment Plant, Main Pump Station and
Sludge Drying Bed Facility;
 Adequate notification will be given to affected residences or businesses at least four weeks
prior to construction, identifying the anticipated length of the disruption, specific impacts to
individual properties and the strategy for providing alternative arrangements for such
properties;
 Dedicated parking and / or alternative access will be provided to clubs and services;
 Coordination to consolidate the transport of equipment and materials to sites that would be
required for construction of pipelines and pumping stations in the event that these occur
simultaneously to minimize traffic movements to sites;
 Where required, temporary access to properties over trenches will be provided by use of
steel plates or similar;
 Access road to construction site to be upgraded to handle construction traffic;
 Trained construction staff to control access and exist movements of construction machinery
from the closed road into open road sections,
 If lane closures along pipe line routes .are required at some locations, stop/go traffic
controls to be provided;
2) Land Use
 The NWSDB is required to provide all the possession of site with the approvals from the
UDA, CEA, and LA for the pipe laying sites from MPS.
 Construction team will investigate the most suitable mechanism to achieve long-term
conservation and proper utilization of the lands for post-construction phase,
136 / 149
Method Statement
 NWSDB is requested to provide a surveyed description of the land required for the site in
consultation with UDA, CEA and LA.
 Nominees to be involved in oversight of wastewater transfer pipeline construction through
RDA roads,
 Steering Committee of the project will to be consulted at all relevant phases of project
design, documentation, construction and operation;
 NWSDB or its Project Director to liaise with landholders well in advance of construction
(during detailed design) to negotiate location of site specific. Infrastructure components, as
required;
 Construction at force main will be undertaken outside peak holiday periods, if possible;
 Construction works to be sequenced and planned as far as practicable, to minimize
cumulative impacts on area amenity;
 At least four weeks notification will be given to affected residences or businesses prior to
construction;
 Provision of alternative access ways and detours to be made around construction areas
during road and footpath closures.
3) Noise and Vibration

 Consultation with property owners/residents around the sites would be undertaken,
providing a communication path directly to the Contractor;
 Noise monitoring to be carried out during the earthworks stage to ensure compliance with
set noise limits;
 Structures are not to be located closer than 20meters to the nearest residence;
 Earthmoving equipment to be fitted with high efficiency mufflers and noise suppression kits;
 All construction works to adhere to stated time restrictions;
 Residents potentially affected by construction works to be kept informed of the schedule;
 Where vibratory rollers are used they must be no closer than 12m from dwellings and a
Class III or medium roller is to be used where possible;
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Method Statement
 The total number of vehicles and plant operating at any one location and at any one time
will be minimized;
 Noisy activities, such as significant earthworks, to be restricted to the hours 7.00 am to
4.00pm Mondays to Friday, and 8.00 am to 1.00pm Saturdays, when within 100meters of
any residence;
 Residents within 300meters of any construction work will be advised of impending activity
and relatively high construction noise.
 Noisy construction to be completed with the minimum of undue delay;
 Noise Consultant appointed by the contractor to assess whether allowable noise levels are
likely to be exceeded and appropriate mitigatory measures to be implemented before
construction commences, wherever feasible;
 The construction contractor to establish and maintain an easily accessible and
well-publicized inquiry hotline;
 In the event that noise complaints are received from nearby land users, each complaint to
be investigated and where noise emissions are established as exceeding the set limits,
appropriate noise amelioration to be put in place to mitigate future occurrences; and
 Where potential vibration impacts exist, construction contractors are to monitor ground
vibration close to the nearest residence until satisfactory vibration levels, have been
demonstrated.
4) Air Quality
 Dust Control Plan to be included within the Construction EMP. This is to include measures
to control dust from construction (for example, water sprays, ceasing work in high wind
conditions) and in transport (for example, covering truck loads);
 Use of water sprays during hot, dry windy days to manage dust from construction. Spray to
be applied to exposed surfaces or potentially dust generating areas, for example, unsealed
access roads and soil stockpiles;
 Stabilization, re-vegetation and landscaping to be carried out as soon as practicable after
construction;
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Method Statement
 Vegetation clearance to be minimized;
 Trucks transporting construction materials to be covered;
 Low speed limits to be set to limit dust generation.
5) Soils and Geological

 Cleaning of erosion control structures to be carried out when accumulated sediment
reaches high level;
 Soil exposure to be limited by vegetation clearance and confining work areas to as small an
area as possible;
 Access to site to be controlled and all machinery kept to designated tracks whenever
possible;
 A designated hardstand area to be provided, where possible, for parking and emergency
on-site maintenance of machinery. Generally, maintenance to be conducted off-site in
appropriate facilities;
 Run-off generated outside of the work area to be diverted around the construction site;
 Run-off generated internally to be intercepted and treated through the use of sediment
filters and traps, straw bales or sedimentation basins;
 Silt fences in areas of high run-off to be reinforced;
 Topsoil and leaf litter on areas to be disturbed to be collected prior to any construction
works commencing, stored separately and replaced as part of site rehabilitation;
 Immediate stabilization of soils following construction using appropriate replanting,
mulching or hydro-mulching;
 Shake-down areas to be provided in access tracks to prevent removal of soil material on
vehicle tires and machinery;
 Discrete layers of soil material to be stockpiled separately for sequential replacement after
construction and avoidance of contamination by bituminous, concrete or other foreign fill
materials. Silt barriers to be provided around all stockpiles to prevent the loss of material;
 Any noxious weeds to be removed by specialist bush generators prior to construction works
commencing;
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Method Statement
 Construction to be restricted to favorable weather conditions; and
 Working areas in the vicinity of wetlands and banks of creeks and waterways to be
minimized as much as possible. Machinery and workers to operate as far as possible
from these areas.
6) Water Issues
 Storm water flows to be diverted around construction sites;
 Erosion control devices to be installed before site stripping commences and regularly
maintained until the disturbed area is effectively rehabilitated;
 Erosion and Sedimentation Control Plan to be prepared and adhered to during
construction;
 Re-vegetation and soil stabilization of cleared areas to be completed as soon as possible
upon the completion of work;
 Water sprays to be used to minimize dust generation;
 Containment basins, pump-out etc. to be used to contain slurries used for thrust boring and
directional drilling activities if adopted;
 The time that soil is exposed to be minimized and other mitigatory measures identified for
erosion and sedimentation control to be implemented ;
 Construction Work is to be phased out to minimize the extent of surface exposure;
 Storage of materials such as soil stockpiles, chemicals, fuel or concrete components to be
in areas away from receiving waters and bounded to contain any spills;
 Any in-stream works are to be referred to KMC and LA for comment should be done three
weeks before commencement of construction;
 Water quality protection measures, such as use of silt curtains and scheduling of
construction works during low flow periods, to be implemented for open-trenched waterway
crossings;
 Ground water liberated during excavation to be contained and pumped out;
 Construction traffic to be restricted to designated access points;
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Method Statement
 The effective design and construction of temporary catch ponds to contain run-off and allow
sedimentation of waters on sites where construction may occur for four weeks or longer;
 Suitable material removed from site to be returned to the site during final landscaping;
 Grassed swales to be used along all drainage lines at construction sites and excess soil
sites transport form and along pipeline routes to reduce run-off velocities and collect
sediment.
 Diversion structures to be provided upslope of the construction sites to divert water running
onto the sites;
 Re-vegetating or hydro mulching of any steep slopes to be carried out as soon as possible
following construction;
 Concrete to be pre-mixed in locations outside the construction sites where-ever possible, to
minimize potential for concrete dust to enter waterways; and
 Storm water to be pumped out and tinkered from site and disposed of appropriately where it
cannot be demonstrated that it can meet acceptable criteria for pollutants of concern (for
example, suspended solids, BOD5, fecal coli forms, phosphorus and nitrogen).
7) Ground Water
 Ground water encountered or produced during excavation will be diverted appropriately so
that the capacity of the drainage paths is not obstructed. Sedimentation will be done as
practicable as possible to reduce solids to acceptable standards before being discharged to
the storm water system or tinkered from site and disposed of appropriately.
8) Visual Impacts
 Measures to minimize visual impacts and improve the aesthetics of scheme infrastructure
are to be assessed and adopted in detailed design for the proposed scheme;
 Pipeline routes to be gradually rehabilitated during construction. All areas disturbed to be
reinstated to as near as possible their original form or similar;
 Flashing lights to be shielded to ensure that there is no nigh-time disruption to adjacent
residences;
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Method Statement
 Access to public use areas to be provided around construction sites where possible;
 Uncontrolled releases of storm water and groundwater to be prevented by appropriate
water retention methods, as identified in the Erosion and Sedimentation Control Plans;
 Public access to work areas to be restricted;
 A vegetation buffer at least 20m wide immediately adjacent to residential zones to be
retained while the excavation is done. Landscaping and re-vegetation to be undertaken
around structures and surrounds to improve the visual character of the area.
9) Health and Safety

 During the construction of the Sewerage Scheme the Principal Contractor, employers and
persons in control of the workplace must ensure adherence to all Occupational Health and
Safety legislation and associated codes and standards.
10) Human and Ecological Risks

 Water produced by dewatering and storm water runoff to be diverted or pumped to the
storm water drainage system. If appropriate levels cannot be obtained, such waters to be
pumped out and disposed of off-site to licensed waste handling facilities.
11) Socio-Economic Impacts

 Pro-active communication with shop owners and adjacent residences to be undertaken to
advise four weeks in advance of the timing, location and potential impacts of the pipeline
works and allow planning to accommodate the requirements of stakeholders wherever
possible;
 Alternative parking and pedestrian access arrangements to be provided to ensure minimal
disruption to land users along the pipeline routes and at pumping station sites;
 Works around clubs and community locations to be scheduled, wherever possible, to be
undertaken during times when these facilities are not active;
 Works to be scheduled such that, as far as possible, they do not coincide with major holiday
periods, particularly near foreshore and public usage areas;
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Method Statement
 A community inquiry hotline to be established and the existing NWSDB customer contact
procedure adopted; and
 Careful facility design, site management and public education to be implemented for
pumping stations in public areas that require the use of chemicals.
12) Risks and Hazards

Risks and Hazards are to be further studied in conducting HIRAC (Hazard Identification and
Risk Assessment and Control) such as buildings to be constructed of fire resistant materials to
minimize fire risk, and others.
10.4. Operation & Maintenance (during Commissioning)
10.4.1. General
Commissioning test period follows right after the pre-commissioning test and has two (2) major
activities, the wet run test and startup. The objective of Commissioning is to prove that the treatment
facilities will operate as designed.
Standard Operating Procedures will be developed to ensure continued facility operation. The
Contractor will keep commissioning test records and forward copies to the Engineer immediately on
request. As Operation and Maintenance manual will be modified in accordance with actual operation
condition experienced during commissioning, all copies of the records will be incorporated in the
Operation and Maintenance Manual to be submitted to the Engineer.
The Contractor will make available all necessary certified instruments, gauges or any other equipment
necessary for checking the installation.
During the course of the test, the Employer, the Engineer and his representatives will have full access
for inspecting the progress of works and checking the accuracy as may be required. The Contractor’s
commissioning team, including contract vendors for equipment and instrument, will have full
coordination with the Employer, the Engineer and his representatives.
The party specifically entrusted with the task of carrying out the test varies with the particular form of
condition of contract involved. These specified persons not limited to the Contractor’s party contract
143 / 149
Method Statement
obligation must be in coordination for the whole duration of commissioning test. These include: (1) the
Contractor’s commissioning team as the main/general contractor including Engineers,
electro-mechanical and instrument technicians, and (2) the Contractor’s contracted vendors for
equipment and instrument.
10.4.2. Commissioning Tests
10.4.2.1. Preliminary Test
The Contractor and his contracted vendors for equipment and instrument will carry out the entire
preliminary tests accordingly and both parties should agree upon the principal issues pertaining to the
contract. This will be disclosed in submitted methodology by the Contractor to the Employer before the
commissioning test to be implemented, namely:
1) The parts of the works to be tested;

2) Types of tests to be carried out and the number of tests;
3) The anticipated duration of each tests;
4) The programming and sequencing of the tests;
5) The details of each tests such as type of readings, number of readings, accuracy and
tolerance permitted, and other relevant details;
6) The rules on the interpretation of the results inclusive of the criteria of acceptability;
7) Identifies the particular of the testers, the recorder of the results/readings, relevant personnel,
and the interpretations of the results/readings;
8) Any other relevant matter or detail.
All necessary tests will be carried out and actual commissioning test will be started only once defect
has been eliminated. The Contractor will issue a letter to the Employer upon successful preliminary
test and once the plant is ready on the actual commissioning test performing the two (2) major
activities.
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Method Statement
10.4.2.2 Wet Run Test and Startup Activities
The Contractor and his vendors for equipment and instruments will be responsible for the operation
and maintenance of the treatment plant during the required commissioning period during the wet run
test and startup activities. The Contractor’s commissioning team together with his operators and
maintenance technicians and equipment and instrument vendors will perform the operation and
monitoring of the treatment process based on the prepared draft of Standard Operating Procedures.
The Contractor’s commissioning team will demonstrate efficient operation and maintenance of the
wastewater treatment plant during the commissioning period in compliance with the project
performance standards subject to following tasks:
1) Operation of the treatment process in coordination with the Employer;

2) Revising the O&M manual to reflect actual operating experience;
3) Training operators;
4) Providing technical briefing to Employer with regards to operation;
5) Reviewing laboratory procedures;
6) Checking process units, flows, etc., to ensure proper operation;
7) Preparing on-going records of plant performance, including tables and graphs, monitoring bio
solids and effluent quality and unit process control parameters;
8) Conducting and preparing preventive maintenance records and subcontractor service reports,
monitoring equipment running time and condition, and instrument calibrations.
10.5. Operation & Maintenance (during the Trial Operation/Performance Testing)
10.5.1. Organization Chart for Operation & Maintenance
The objective of the services proposed hereof is Operation& Maintenance Works in accordance with
Bid requirement. The Contractor will assign 6 staffs including the Plant Manager who works for the
Contractor as representative at site, and the Plant Manager will stay at site during work time for
operation management. Under the Plant Manager, Operation Group and Maintenance Group will be
organized and total 8 operators (3 shift 4 teams) and staffs will be assigned at site.
The Maintenance Group will implement regular and routing servicing, maintenance services and
inspections. Operations and Maintenance Program will be submitted later.
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Method Statement
10.5.2 Spare Parts and Special Tools for Operation and Maintenance
1) Spare Parts
Anticipated spare parts list will be submitted later.
This list is for 5 years of Operation & Maintenance.
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Method Statement
2) Special Tools
The Contractor provides special tools listed below preliminarily.
No. Item Capacity Size Qty.
1 Mobile floor crane manual type Capacity 200kg 1unit
2 Hand Truck (trolley) Capacity 200kg 1unit
3 Tool Cabinet Capacity 15kg 1set
4 Grease Gun 85cc 1set
5 Water hose reel 30m 1set
6 Wire Brush 50mm 1set
7 Safety Goggle - 3 sets
8 Sound Level Meter 130dB 1set
9 Volt-ampere tester AC/DC - 1set
10 Electrical Code reel 30m 1set
11 Mechanical Tool Set 1set
1) Tool Box - 1set
Double ended open jaw
2) 20 to 36mm 1box
wrenches
3) Combination wrenches 16 to 28mm 1set
4) Double ended ring 24 to 36mm 1set
5) Hexagonal socket screw 1.5 to 12mm 1set
6) Socket set 10 to 34mm 1set
7) Rubber hammer 2 Ibs 1set
8) Universal Pliers 1set
9) Cutting Pliers 1set
10) Locking Pliers-Chain Clamp 1set
11) Wire Stripper 1set
12) Electronic Pliers 1set
13) Pipe Wrench 1set
14) Adjustable Wrench 1set
15) Screw Driver Plus 1set
16) Screw Driver Minus 1set
17) Hexagon key set 1set
18) Hacksaw 1set
19) Tapes 5m length 1set
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Method Statement
20) Tapes 30m length 1set
10.5.3 Monthly Report and Daily Analysis

The Contractor will record daily operation logs and summarize as a monthly report. No later than
fifteen days after end of that month, the will submit the monthly report to the Engineer.
The Contractor will conduct the Daily Analysis of influent and effluent quality to check operation
condition using laboratory equipment which is equipped in the laboratory room. The result will be
included in the monthly report.
10.5.4 Training Program

The Contractor will provide a comprehensive Facility Training program as part of this Contract. The
purpose of the Facility Training shall be to train the Employer and Employer’s Operators in the overall
operation and maintenance of the facility. Facility Training will involve a combination of Classroom
Training and On-the–Job Training.
The Facility Training program will include providing English and Sri Lankan speaking personnel,
training aids, manuals and other materials. The Contractor will assigned training personnel who have
at least 10 years operation experience of similar facilities.
1) Classroom Training
The Classroom Training period will be for 5 work days over a one week period. These sessions will
cover the treatment facility as the main area and also cover inlet gates and other controlled devices
on the interceptor delivering wastewater to the treatment plant. The topics to be taught are as
follows;
(1) Basic theory and principles

(2) Special features of equipment
(3) Start-up procedures
(4) Routine operation and operation under surcharge conditions
(5) Normal shut-down and emergency shut-down procedure
(6) Safety procedures and awareness
(7) Maintenance management system
(8) Periodic reporting by SCADA system
(9) Troubleshooting
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Method Statement
2) On-the-Job Training
On-the-Job training (hereinafter called OJT) will be conducted for the whole trial operation period.
OJT will be for 24 hours per day for the duration. During OJT, the Contractor will operate the
facilities in the presence of the long-term operations personnel as provided by the Employer. At the
end of this period, the long term operations personnel are able to take operation tasks under the
Contractor’s observations.
The OJT will proceed without undue interruption. Minor interruptions which are attended promptly
by the Contractor will be acceptable. In the case of major interruption the period of OJT will be
extended to make up for the loss in time due to rectification work at no additional cost to the
Employer.
10.5.5 Exit Test
Before end of the Operation & Maintenance period, the Exit Test shall be carried out by the
Contractor. The Exit Test shall be conducted same as the Performance Test.
The Employer and the Contractor will select an independent, technically qualified engineering or
consulting firm to conduct a complete plant audit for the purpose of determining the condition of
each and every part of the Facilities. An estimated cost for repair, renewal or replacement, even if it
is judged to be deficient in upkeep and maintenance, shall be borne by the Employer except the
cost of items which affect the performance of the functional guarantee.
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JFE Engineering Corporation National Water Supply and Drainage Board

Contractor Employer Engineer’s Representative

2. Design General Requirements ......................................................................................................... 10

3. Material Procurement ........................................................................................................................ 17

4. Quality Control ................................................................................................................................... 23

5. Progress Control ............................................................................................................................... 25

5.4. Weekly Meetings .............................................................................................................. 25

6. Safety and Risk Management ........................................................................................................... 30

7. Safety Plan ......................................................................................................................................... 38

8. Environmental Management Plan .................................................................................................... 38

9. Division of Works .............................................................................................................................. 38

10. Work Methodology ........................................................................................................................ 41

10.2. Pipeline Works ............................................................................................................... 108

(ix) Sludge Drying Bed Building at SDB

Definition and Abbreviation

Following abbreviation and/or word shall be applied in this document.

1.1. Contractor’s Organization

1.2. Project Scheduling

1.3. Progress Report

1.5. Construction Mobilization

1.5.1. Mobilization for Temporary Facilities

1.5.2. Mobilization for Construction Start-Up

2. Design General Requirements

2.1. General Approach to Design

Design Data Validation and Site Surveys – Review of Preliminary Design

Civil, Building and Structural Designs

Main Pumping Station

Force Main Pipeline

Mechanical – Electrical Designs

a. Preparation of process design arrangement of process units and connections.

2.2. Documents and Drawings for Submission to the Employer

Documents, such as Project Schedule, Progress Reports, Design Computations, Material

All contact point correspondence shall be addressed as follows:

Project Manager as Contractor Leader assigned by JFE Engineering Corporation

2.3. Review and Approval of Documents and Drawings

1) Correspondences between Employer, Engineer and the Contractor

(1) LETTER or TRANSMITTAL

(2) NOTICE / INFORMATION and QUERY

(3) DOCUMENT TRANSMITTAL

(4) ACKNOWLEDGEMENT OF RECEIPT

(5) REPLY TO THE COORESPONDENCES

(6) MINUTES OF MEETING

(7) E-MAIL COMMUNICATION

2) Format of Technical Drawing and Document

APPD CHEKD CHEKD CHEKD DRAWN Date

(Name) (Name) (Name) (Name) (Name) SCALE

FOR (Client’s Name)

JOB TITLE xxxxxxxxxxPLANT

DWG TITLE GENERAL ASSEMBLY DWG FOR xxxxxxx

JOB CODE DOC.NO.

(Each Company’s Name)

(3) Cover Sheet of Technical Document

Cover sheet of technical document shall be followed this document.

(4) File name of Electrical Data

3.1. Qualification and Selection of Suppliers, Manufacturers, and Subcontractors

(1) Requisition including technical specification and/or drawings

3) Evaluation of Suppliers Quotations

3.2. Review and Approval of Materials and Equipment to be Used

Material Specifications, Catalogues, and Brochures will be submitted by Contractor to the

1) Placement of Purchase Order

2) Meeting with Vendor or Supplier

3) Progress Monitoring and Expediting

4) Procurement Quality Control