HATJR HDPE INSTALLATION

PROCEDURE
Doc. No.: PMG-03-010
MCS CORPORATION Revision Code: 0 Page 1 of 5

Project
: S2 PROJECTS Effectivity: May 14, 2021
Title

Location : Balibago Sta. Rosa City, Laguna

Subject : HDPE INSTALLATION PROCEDURE

HDPE INSTALLATION PROCEDURE

1.1 TOOLS REQUIRED FOR HDPE PIPING INSTALLATION

 Mechanical Hand Tool

 Cutting Tools

 Drilling Machine

 HDPE butt fusion and welding machine

1.2 HOW TO INSTALL HDPE PIPE INSTALLATION METHOD STATEMENT

1.2.1 Suitable lifting equipment i.e. Boom truck/ Chain Block shall be used to shift the pipes
from stored place to the installation site. All necessary safety precautions as per established
safety procedure shall be implemented during shifting and installation.

1.2.2 The pipe lengths shall be cut according to the approved shop drawing, and shall be
joined using butt fusion welding and electro-fusion welding as applicable.

1.3 JOINTING OF HDPE PIPING

1.3.1 Smaller diameter HDPE pipes i.e. up to 75-mm will be joined using the hot plate
welding, while the pipes above 75-mm shall be joined using a butt fusion machine

1.4 HDPE ELECTROFUSION WELDING

For HDPE electro-fusion welding, HDPE accessories are provided with spigot
ends. The spigot ends are provided with low irregularities and the welding sleeve has
projections to allow their exact distance apart to be determined.

1.4.1 The HDPE electro-weld sleeve is provided with 2 socket ends which can be welded in a
single operation.

1.4.2 The welding equipment sends current through the resistance wires in the electro-weld
socket for a set period. Both eletro-weld sockets are welded at the same time.

1.4.3 The electroweld socket has stops on the interior. The socket has two contact pins on the
outside for the connection of the welding equipment.

1.4.4 There are two welding indicators which appear during and after the welding operation.
These indicate that the welding has been reached and that the welding pressure has been
applied.

1.4.5 The connector cables from the welding equipment should be connected to electro-weld
socket.

1.4.6 This will illuminate “connection” indicator lamp.

 HATJR HDPE INSTALLATION
PROCEDURE
Doc. No.: PMG-03-010
MCS CORPORATION Revision Code: 0 Page 2 of 5

Project
: S2 PROJECTS Effectivity: May 14, 2021
Title

Location : Balibago Sta. Rosa City, Laguna

Subject : HDPE INSTALLATION PROCEDURE

1.4.7 Press the start button. The welding indicator lamp will illuminate. Once the welding time
is complete the lamp automatically extinguishes and the current supply switches off.

1.4.8 Check the weld indicators. They should have emerged by around 2mm.

1.5 WELDING OF HDPE PIPES

In butt welding (pipes 75mm and smaller) both pipe ends are placed against a
hot plate at a constant temperature and pressure.

The plastic pipe ends are now pressed together so that the molecules of the material
are transferred between them.

Before starting hot plate welding the equipment shall be checked for the following
items:

1.5.1 The hot plate temperature must be 210 C.

1.5.2 The hot plate must be clean and free of grease.

1.5.3 Ensure that the two pipe brackets and the two pipe supports are correctly aligned.

1.5.4 Both pipe clamps must be adjusted so that they hold the pipe tightly enough to
withstand the force of the welding process.

1.5.5 Press the pipe ends against hot plate by briefly applying a high pressure. Continue
heating very low pressure until an up stand of 1 mm has formed.

1.5.6 Quickly remove the hot plate and slowly increase the welding pressure.

1.5.7 Hold the welding pressure steady and allow the weld to cool.

1.5.8 Remove the joint and inspect the weld. An irregular weld seam should be rejected.

1.6 PRESSURE TESTING

1.6.1 Identify the test loops for the completed line system wise.

1.6.2 Test packages shall be prepared with all welding / summary, P & ID marked with Test limits,
Isometric drawings, support details etc. for the completed lines of the system and submitted for
client’s approval.

1.6.3 The Test Pack documentation shall contain isometrics or relevant pack of pipe work related to
package of piping system that is bearing tested and shall include following information:

 Limit of test as illustrated on the P& ID’s

 Location and thickness of test spades

 Test medium, Test pressure, location of vent and drains

 HATJR HDPE INSTALLATION
PROCEDURE
Doc. No.: PMG-03-010
MCS CORPORATION Revision Code: 0 Page 3 of 5

Project
: S2 PROJECTS Effectivity: May 14, 2021
Title

Location : Balibago Sta. Rosa City, Laguna

Subject : HDPE INSTALLATION PROCEDURE

 Requirements for isolation or removal of in-line equipment and instruments.

1.6.4 Inside of all pipes, valves, fittings and other associated equipment are clean and free from loose
foreign matter prior to commencement of the pressure test.

1.6.5 Upon obtaining mechanical clearance and test packages approval, Hydrostatic test shall be
carried out as per project specification.

1.6.6 Test package shall be prepared as per method statement and procedures.

1.6.7 In-line instruments, control valves, manual block valves, special items, etc. that may interfere
with a proper pressure test or might be damaged during test, shall be not be installed before pressure
test for fit-up and or shall be removed for the test and substituted with temporary spools.

1.6.8 Temporary test gaskets shall be installed for the test on location with temporary blinds or spools.
However permanent gaskets may be used for the flanged joints which will remain unopened during
and after pressure test. Screwed tapping, for example in orifice flange sets, shall be plugged.

1.6.9 Non-return valves, if installed, will require that the piping network be pressurized from the
upstream side.

1.6.10 High point vents to release air from the system whilst filling with the test medium and low point
drains, either valve or plugged.

1.6.11 Two pressure gauges (minimum) shall be used for the test. The gauges shall be calibrated and
certificate attached to test package before pressure test. The maximum range of gauge will be 1.5 to
4 times of the test pressure.

1.6.12 Once the pressure of the line is stable, inspection of the line shall commence. The test
pressure for process or power pipe work shall be for a minimum of 30 minutes or as required to
inspect the line.

1.6.13 In case of leakage, the line shall be retested after repair according to the related procedure.

1.6.14 When the test has been successfully completed, lines are de-pressurized by operating vent
valves gradually. Then the complete discharging of the system through the drain valves is taken up,
keeping the vent valves always open. The line shall be de-pressurized and drained completely.

1.6.15 All test blinds shall be removed and the line shall be reinstated with permanent gaskets.

1.6.16 Hydrostatic test shall be followed under code: Hydrostatic test procedure of piping.

1.7 FLUSHING

1.7.1 After completion and approval of hydrostatic testing of the system, all lines and equipment shall
be drained and flushed.

1.7.2 Special attention shall be given to points where water and sediments may be trapped, such as
valve bodies or low points.
 HATJR HDPE INSTALLATION
PROCEDURE
Doc. No.: PMG-03-010
MCS CORPORATION Revision Code: 0 Page 4 of 5

Project
: S2 PROJECTS Effectivity: May 14, 2021
Title

Location : Balibago Sta. Rosa City, Laguna

Subject : HDPE INSTALLATION PROCEDURE

1.7.3 Piping completed the Pressure Testing shall be internally cleaned to remove all remaining
foreign matter by water flushing or blowing with air.

1.7.4 Flushing shall be done with water.

1.7.5 Instruments shall not be flushed through.

1.7.6 Piping and equipment shall be dried and all traces shall be removed as per project
specifications.

1.8 RE-INSTATEMENT

1.8.1 After successful completion of pressure testing, flushing and draining, the system shall be
returned to a state of commissioning readiness as per drawing specifications and Project requirement.

1.8.2 All temporary materials such as spades, blinds, gaskets and temporary supports should be
removed from the system.

1.8.3 All spectacle blinds should be repositioned to the correct position as per the P&ID.

1.8.4 All accessible points of the system shall be inspected to ensure that it is free of scale, rust, loose
paint and film and is of correct surface appearance.

1.8.5 All items those were removed from the system before hydrotest such as control valves, inline
instruments etc. should be re installed after hydrotest and flushing.

1.8.6 All punch items should be removed and all test vents should be seal welded.

1.8.7 All completed system should be inspected for the correct flow direction in piping and
instruments.

1.9 HEALTH, SAFETY AND ENVIRONMENT

1.9.1 In Workshop

1.9.1.1 The CONTRACTOR Workshop Safety Procedures shall be strictly followed by all employees
and personnel.

1.9.1.2 Safety Plan at Workshop will be covered by the Contractor, Safety and Environmental
Management System.

2.0 At Site

2.1 CONTRACTOR HSE Manager/ Safety Officer shall ensure that the work is performed accordance
to the approved Construction Safety Manual and precautions specified in the work permit. He shall
ensure that barricades, warning tapes, warning signs, firefighting equipment’s and first aid kits are
readily available at the working area.

2.2 Tool box Meeting shall be conducted on a daily basis to inform the workers of the recent safety
issues and incidents and to get feedback of any unreported unsafe acts. Feedback will then be
processed and resolved.
 HATJR HDPE INSTALLATION
PROCEDURE
Doc. No.: PMG-03-010
MCS CORPORATION Revision Code: 0 Page 5 of 5

Project
: S2 PROJECTS Effectivity: May 14, 2021
Title

Location : Balibago Sta. Rosa City, Laguna

Subject : HDPE INSTALLATION PROCEDURE

2.1.1 Accident Prevention Safety Procedures

2.1.2 Area shall be barricaded adequately with warning barriers prior to any lift.

2.1.3 All Equipment shall be checked for good conditions before commencing the work.

2.1.4 Unauthorized persons shall not allowed on the area.

2.1.5 Lifting equipment capacity and correct load slinging will be verified.

2.1.6 When lifting, the personnel shall not remain in the lifting equipment work area.

2.1.7 Adequate standards shall be adopted for the construction of stages, planks, scaffolds, etc.

2.1.8 Adequate caution boards and warning signs shall be provided.

2.1.9 Trained fire watchers shall be appointed as per requirement.

2.1.10 Sufficient fire extinguishers shall be provided close to the welding, cutting and other hot works.

2.1.11 Welding areas shall be covered with fire blankets.

2.1.12 Consumable materials within 15 meters of welding operation shall be cleared.

2.1.13 Application, maintenance, storage of electric, and oxygen cutting welding units shall conform to
applicable standards.

2.1.14 Do not stand under suspended loads.

2.1.15 On completion of job, the area shall be cleared of any materials and keep clean and tidy.

2.1.16 Hazard analysis for hazardous operation shall be carried out prior to commencing the works.

Prepared by: Reviewed/Approved by:

Engr. Jessie P. Suligan Engr. Tirso P. Suligan

HATJR PMG Head General Manager