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Revision History
Re Prep Chec Revie Approv
Date Revision Details
v. ared ked wed ed
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Categ Contents Pa
ory ge
1 Scope of work
2 Tool & Equipment
3 Work sequence
4 Inspection
5 Test & Commissioning
Appen
dix 1
Appen
dix 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
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2. Tool & Equipment

- Mini Backhoe (optional)

- Portable Genset
- HDPE Welding Machine

3. Work Sequence
The following procedures are the working method for laying of
HPDE pipes under the proposed construction site Depot Site
Devt. Utilities, 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 Mini
Backhoe to the depth specified on the drawings with minimum
width specified on the plans. The slope shall be set at 45
degrees angle in order to ensure stability.
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.
- 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.
- 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.
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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

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 the pipes. 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.
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- 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)
 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.
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 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

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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.

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

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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.

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.
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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

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
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WELDING PROCESS

1. Clean inside & outside of both ends at the welding

joint with dry cloth then set level and alignment with
clamping device.
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2. Set the squareness of contact surfaces at both ends

with peeling tool.

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.
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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.

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
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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

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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 23
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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

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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 25
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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

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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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