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Revision History
Rev. Date Revision Details Prepared Checked Reviewed Approved

Category Contents Page

1 Scope of work
2 Tool & Equipment
3 Work sequence
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4 Inspection
5 Test & Commissioning
Appendix 1
Appendix 2

1. Scope of work
This method statement is prepared to outline the procedure for installing of HDPE UG pipes of Utility Water
System and other system mentioned below :
- Waste Water System
- Chemical Waste Water System - Fire Fighting Water System
- Service Water System

2. Tool & Equipment

Construction Machinery
- Dumper
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- Crawler Excavator
- Backhoe
- Hiab Truck
- HDPE Welding Machine

3. Work Sequence
The following procedures are the working method for laying of HPDE pipes under the proposed construction
site of Clarifiers Tanks, there are three main steps which are:
3.1 Excavation
The excavation shall be carried out in two steps. The first step is to open the ground up at 45
degrees by using a crawler excavator to the depth of 1.15 m plus 0.744 m with minimum width of 0.7m. The
slope shall be set at 45 degrees angle in order to ensure stability and to increase ventilation and access
(including stair access). The designated degree of opening should not make the excavated trench a
confined space.
When the excavation of the first level has been completed then the next level shall be continued by
creating a step which would extrude outwards for half a meter. The crawler excavator would then dig down
for another 1.2 m to the proposed level with the width at the bottom of the trench shall be set at 1m.
The general requirements for standard specification are as follows:
- The levels for excavation shall be established by the surveyor.
- Any existing structure, cable, or pipe must be identified before any excavation work can be done. However,
this site is a green site so no such existing can be found.
- The dimension of excavation shall be depended on the size of the HDPE Pipe.
- Excavated material shall be hauled to be inspected by qualified person to a dumpsite, however, excavated
material shall be moved to a dump site or if it is required to be store for further backfill then material must
be a stock area.
- There must be a bank man and rigger for each vehicle to control the vehicle in order to prevent injury to
other workers and damage to the vehicle itself.
- If there is any surface or ground water, it shall be pumped out from excavated areas to avoid flooding
excavated site.
- Stable slope must be over 1.5 m
- Safety sign, hard barricade, lighting if working at night would be required around the working area.
- When the excavation nearly reaches its designated level, care shall be taken in order to save time and cost
if the excavated level is too deep.
- When excavation reached it design level then the engineer must be informed.
- If the excavated level is over 1.5 m then daily inspection shall be required (Refer to DOW Specification and
Safety Standard)

3.2 Welding of HPDE pipe

After the excavation and compaction of the ground have been completed, then HDPE pipes shall
later be laid on the sand bag in order to adjust and lock the pipes into position.
The HDPE pipes shall be connected by using Butt fusion welding technique. Refer to technical information
for HDPE Butt Fusion Welding in Appendix II.

3.3 Sand Compaction

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The compaction shall be carried out in order to prepare the ground for HDPE pipe foundation. The
next part of compaction is when the HDPE pipes have been laid and materials backfilled to a designed level
which is approximately 2.5 m from the bottom of thepipes. The compaction must be done at 90% standard
ASHTO with laboratory CBR at ≥ 4%.

3.4 Hydro Test

Pressure Test Procedure

3.5 Backfill
The majority of material for backfill shall be sand which covered the HDPE pipes up to 1.2 m from the lean
level while the rest of the backfill material would be original material from the excavation. The excavator
shall be used to backfill the rest of the trench to the new designated ground level then the compaction
process shall carry out to get the optimum level of compaction to the standard set in the general
specification in order to prepared the ground for concrete lean.

The general requirements for standard specification are as follows:

- Excavated material must be hauled from stacking area by priority if material can be reused.
- If the material is coming from outside then the foreman/ supervisor must inform engineer before use.
- The material must be covered if the material is coming from outside while transporting.
- If the original slope is steeper than 1 to 1 then natural file shall be scarified so that refilled material can be
bonded with existing.
- Filling material shall be placed evenly and in depth of more than 300mm. for compaction.
Material shall later mixed with water and evenly compacted
- Compacted material at the optimum content shall be determined in accordance with general specification.
- Each fill layer shall be compacted to 90% of maximum dry density in case of general specification drawing.
- The moisture content of all compacted structural backfill shall be within 0 and +2percent of the optimum
moisture content measured in accordance with general specification.
- Backfill for structure shall be executed after the concrete will attain at least 60% of the 28-day compressive
strength or a minimum period of 7 days.

4. Inspection
4.1 Material check
4.2 Alignment check
4.3 Pipe line check

5. Test & Commissioning

PRESSURISING METHOD AND HOLDING TIME
 Pressurize to 25% of test pressure (hold time 5 min)
 Up-pressure gradually to 50% of test pressure (Hold time 5 min)
 Up-pressure gradually to 75%of test pressure (Hold time 5 min)
 Up-pressure gradually to 100% of test pressure (Hold time 15 min)
 Up-pressure gradually hydro test pressure (1.5 time of design pressure, Hold time 15 min)
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 Visual check signal of leakage test and follow up chart recorder.

 Reduce pressure gradually hydro test pressure (Hold time 5 min)
 Record pressure being held long enough and de-pressure to atmosphere.
 Drain out test water. The pressure shell be decreased at a rate of not more than 2 bar per minute up to
the atmospheric pressure by slowly open the drain valve.
 The water for hydrostatic test will also be disposed
 Uninstall all test equipment and carry out reinstatement.

FLUSHING PROCEDURE
 Flushing of all lines shall be done after hydrostatic test and was supervised by commissioning
personnel.
 Flushing of all lines shall be done in the presence and as per the approval of the Owner.
 The medium for flushing used de-mineral water. Flushing of pipe lines will be done by start condensate
water pump and use water temporary tank in PURAC.
 During flushing care must be taken so that the pressure is lower than the operating pressures. The
pressure for flushing around 1.90 bar.g
 3.5 Flushing will be continued until the inside of the pipe is fully cleaned. The flushing test result shall
confirm by Owner.
 During the flushing, discharged water. Care shall be taken during flushing so as not to damage / spoil
other agencies work. Precautions shall also be taken to prevent entry of water in the vicinity of lines
being flushed.
 The water will be flush into drainage system of Power Plant. After flushing the temporary installed
piping and other spool piece shall be removed. Piping equipment and instrument removed for flushing
the line shall be re-installed in the collect position using prescribed gasket.
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Appendix I : Butt Fusion Welding Procedure

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METHOD STATEMENT FOR HDPE PIPE

1. Pipe Alignment: Place pipe and fitting on the clamping device and set pipe level
by screwing until both pipes are in the same level and line. The misalignment shall
not exceed 0.1 x wall thickness of the pipe.

Figure 1.1 Figure 1.2

2. Pipe Trimming: Trim the surplus plastic around welding surface by peeling tool.

peeling tool

Figure 2.1 Figure 2.2

3. Inspection Before Welding: Final level and alignment.
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Figure 3.1
Heating Plate
Figure 3.
4. Cleaning Before Welding: Clean the surplus plastic after trimming by using clean cloth, tissue with methyl
alcohol to remove oil and dust at pipe and heating plate and heat up to 210° C

Figure 4.1 Figure 4.2

5. Butt Fusion Welding:

5.1 Press both pipes or fitting to the heating plate until melt and welding seam appears.
Release pressure but keep heating pipe and still stick with the heating plate according to
the heat soak time.

Figure 5.1 a Figure 5.1 b

5.2 Remove heating plate within change over time.

5.3 Slide the pipe ends to connect each other within max pressure rising-time.
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5.4 Increase welding pressure as per welding specification.

bar

Figure 5.2 Figure 5.3 Figure 5.4

6. Cool Down Time: Let the welding joint cool down but maintain the pressure according to welding
specification until it is cool… Finished welding process

Fig 6.1 - Welding Specification Table.

Fig 6.2 - Let the welding joint cool down according to the specification and maintain pressure.
Fig 6.3 - Remove the pipe from clamping device.
Fig 6.4 - Weld seam width must be conformed to welding specification.

Welding Specification Table

Wall/Joints Weld Height Heating Time Remove Time unstable Time stable
Thickness Heating Pad Pressure Pressure
(mm.) (mm.) (sec.) (sec.) (sec.) (sec.)

2.0 - 4.5 0.5 30 - 70 3 3-6 3-6

4.5 - 7.0 1.0 70 - 120 4 4-8 6 - 10

7.0 - 12.0 1.5 120 - 190 5 8 - 10 10 - 16

12.0 - 19.0 2.0 190 - 250 6 10 - 15 16 - 24

19.0 - 26.0 2.5 250 - 330 7 15 - 20 24 - 32

26.0 - 37.0 3.0 330 - 490 8 20 - 25 32 - 40

37.0 - 50.0 3.5 460 - 600 17 25 - 35 40 - 45

Figure 6.1

bar

Figure 6.2
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Figure 6.3
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Figure 6.4
GENERAL INSTRUCTION OF WELDING WORK

1. Check pipe diameter, thickness and fitting to prepare the proper welding machine.

2. Before welding, the welding machine must be inspected as well as electricity,

hydraulic system, pressure gauge and also require the machine calibration
certificate.

3. Check working condition and protect raining, moisture and dust in order to obtain high quality
work.

4. Check heating plate temperature and clean with methyl alcohol.

5. Remove any oil from heating plate and both ends of welding joint.

6. Proceed work according to welding procedure and maintain equipment in good condition.

7. The welder must be well trained and obtained certificate from standard institute.
PARTS OF WELDING MACHINE
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1. Clamping device
2. Heating plate

3. Hydraulic pump

4. Peeling tool

WELDING PROCESS
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1. Clean inside & outside of both ends at the welding joint with dry cloth then set level and
alignment with clamping device.

2. Set the squareness of contact surfaces at both ends with peeling tool.
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3. Clean the contact surfaces of both ends of welding joint and heating plate to be free of oil,
debris etc. then set the temperature of heating plate at 200‐220° c.

4. When the heating plate reached the specified temp., then put the heating plate between
the both ends of welding joint and set heating up pressure as per attached welding
parameter.
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5. Wait until the both endes of HDPE pipe is melted and have weld seam width 1‐3 mm. around
pipe.

6. Release pressure and leave it to the heat soak time then move the heating plate out
within change over time and move both ends back to contact each other within max.
Pressure rising time as per attached parameter.

7. Keep constant welding pressure and leave it under cooling time under pressure as
per welding specification.
8. Then release clamping device.
9. Finished welding process.

WELDING CYCLE
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Figure 1 Shown Butt Fusion Welding Cycle

Step 1 Clean and set alignment of HDPE pipe then set heating plate temperature at 200‐
220 °c.
Step 2 Set heating up pressure until have weld seam 1‐3 mm around pipe.
Step 3 Release pressure and leave it to heat soak time.
Step 4 Move heating plate out within change over time and move both ends of pipe back
to contact each other within max pressure ‐ rising time.

Step 5 Increase welding pressure.

Step 6 Cool down under constant welding pressure.
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WELDING SPECIFICATION

OD mm 63 75 90 110 160 200 225 250 280 315 355 400 450 500 560 630 710
ND IN 2" 2 1/2" 3" 4" 6" 7" 8" 9" 10" 12" 14" 16" 18" 20" 22" 24" 28"
PN (PE 100) 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
WALL THICKNESS (e) mm 3.8 4.5 5.4 6.6 9.5 11.9 13.4 14.8 16.6 18.7 21.1 23.7 26.7 29.7 33.2 37.4 42.1
PIPE X‐SECTION AREA
sq.mm 707 997 1,435 2,144 4,492 7,032 8,908 10,936 13,736 17,407 22,133 28,018 35,507 43,881 54,946 69,628 88,337
(A1)
WELDING M/C TYPE 110 110 110 315 315 315 315 315 315 315 450 450 450 500 800 800 800
CYLINDER X‐SECTION
sq.mm 653 653 653 855 855 855 855 855 855 855 1351 1351 1351 1351 1890 1890 1890
AREA (A2)
HEATING PLATE TEMP. °C 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10 210±10
HEATING ‐UP PRESSURE. bar 1.9 2.7 4 5 9 15 19 23 29 37 29 37 47 58 52 66 84
HEAT SOAK TIME min. 0.95 1.13 1.35 1.65 2.38 2.98 3.35 3.7 4.15 4.68 5.28 5.93 6.68 7.43 8.3 9.35 10.53
CHANGE OVER TIME sec. 3.63 3.75 3.9 4.1 4.6 5 5.25 5.5 5.8 6.15 6.55 7 7.5 8 8.6 9.3 10.1
MAX. PRESSURE ‐RISING
sec. 4. 9 5.25 5.7 6.3 7.8 9 9. 5 10.5 11.4 12.45 13. 5 15. 0 16. 0 18. 0 19. 0 21.9 24. 0
TIME
WELDING PRESSURE bar 1.9 2.7 4 5 9 15 19 23 29 37 29 37 47 58 52 66 84
COOLING TIME UNDER
min. 6.8 7.5 8.4 9.6 12.5 14.9 16.4 17.8 19.6 21.7 24.1 26.7 29.7 32.7 36.2 40.4 45.1
PRESSURE
WELD SEAM (MIN) mm. 4.9 5.3 5.7 6.3 7.8 9 9.7 10.4 11.3 12.4 13.6 14.9 16.4 17.9 19.6 21.7 24.1
WELD SEAM (MAX) mm. 7.9 8.4 9.1 10 12.1 13.9 15.1 16.1 17.5 19 20.8 22.8 25 27.3 29.9 33.1 36.6
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Appendix IV : Quality Control Checklist

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INSPECTION REPORT

Doc. No. : REN-E-SM-10-TM-000-0003

REN KORAT ENERGY PROJECT Page 31 of 34
Rev. No. : C / Date : 20 July 2023

PROJECT : REN KORAT ENERGY PROJECT DATE :

DESCRIPION : INSPECION REPORT FOR INSTALLATION WASTE WATER UG PIPE

ATTENDANCES : REN KORAT ENERGY , EGCO ENGINEERING & SERVICE , TIME :
ITALTHAI ENGINEERING

SUBJECT : MECHANICAL SYSTEM

Package No. _

Report No._ _

Work Location : Area : _

Drawing No. / Rev. _ _

Acceptable
Item Description Comments
Yes No N/A

1 Material Inspection

2 Installation Process

- Underground Waste Water Pipe Hanger and Support

- Underground Waste Water Pipe Location and Routing

- Installation of Underground Waste Water Pipe

- Final Inspection after Complete Installation

Testing of Installed Underground Waste Water

3
Pipe

- Hydrostatic Pressure Test

Inspected by Witnessed / Approval Witnessed / Approval

_ _ _
( ) ( )
( ) Date : _ Date : _
Date : EGCO Engineering & Service Co., Ltd. REN Korat Energy Co., Ltd.
Italthai Engineering Co., LTD.
 Title : Page 20 of 22
Document No. : Effective Date : Revision :

INSPECTION REPORT

Doc. No. : REN-E-SM-10-TM-000-0003

REN KORAT ENERGY PROJECT Page 32 of 34
Rev. No. : C / Date : 20 July 2023

PROJECT : REN KORAT ENERGY PROJECT DATE :

DESCRIPION : INSPECION REPORT FOR INSTALLATION FIRE WATER UG PIPE

ATTENDANCES : REN KORAT ENERGY , EGCO ENGINEERING & SERVICE , TIME :
ITALTHAI ENGINEERING

SUBJECT : MECHANICAL SYSTEM

Package No. _

Report No._ _

Work Location : Area : _

Drawing No. / Rev. _ _

Acceptable
Item Description Comments
Yes No N/A

1 Material Inspection

2 Installation Process

- Underground Fire water Pipe Hanger and

Support

- Underground Fire water Pipe Location and

Routing

- Installation of Underground Fire water Pipe

- Final Inspection after Complete Installation

Testing of Installed Underground Fire water Pipe

3

- Hydrostatic Pressure Test

Inspected by Witnessed / Approval Witnessed / Approval

_ _ _
( ) ( )
( ) Date : _ Date : _
Date : EGCO Engineering & Service Co., Ltd. REN Korat Energy Co., Ltd.
Italthai Engineering Co., LTD.
 Title : Page 21 of 22
Document No. : Effective Date : Revision :

INSPECTION REPORT

Doc. No. : REN-E-SM-10-TM-000-0003

REN KORAT ENERGY PROJECT Page 33 of 34
Rev. No. : C / Date : 20 July 2023

PROJECT : REN KORAT ENERGY PROJECT DATE :

DESCRIPION : INSPECION REPORT FOR INSTALLATION SERVICE WATER UG PIPE

ATTENDANCES : REN KORAT ENERGY , EGCO ENGINEERING & SERVICE , TIME :
ITALTHAI ENGINEERING

SUBJECT : MECHANICAL SYSTEM

Package No. _

Report No._ _

Work Location : Area : _

Drawing No. / Rev. _ _

Acceptable
Item Description Comments
Yes No N/A

1 Material Inspection

2 Installation Process

- Underground Service water Pipe Hanger and Support

- Underground Service water Pipe Location and Routing

- Installation of Underground Service water Pipe

- Final Inspection after Complete Installation

Testing of Installed Underground Service water Pipe

3

- Hydrostatic Pressure Test

Inspected by Witnessed / Approval Witnessed / Approval

_ _ _
( ) ( )
( ) Date : _ Date : _
Date : EGCO Engineering & Service Co., Ltd. REN Korat Energy Co., Ltd.
Italthai Engineering Co., LTD.
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