LIST OF CONTENTS

1.0 PURPOSE .............................................................................................................................. 4

2.0 SCOPE .................................................................................................................................. 4
3.0 DOCUMENT CONTROL ......................................................................................................... 5
4.0 DEFINITIONS, TERMS AND ABBREVIATIONS ........................................................................ 5
5.0 RESPONSIBILITY ................................................................................................................... 6
6.0 REFERENCES ......................................................................................................................... 8
7.0 Testing and Commissioning Work........................................................................................ 8
7.1 Work Preparation. ............................................................................................................... 8
7.2 Work Execution ................................................................................................................. 17
7.3 Work Inspection................................................................................................................. 19
8.0 Safety & Hazard Plan ......................................................................................................... 19
8.1 Hazard Identification ......................................................................................................... 19
8.2 Preventive Measures ......................................................................................................... 20
9.0 Records .............................................................................................................................. 20

Appendix A Inspection & Testing Plan

Appendix B Standard Forms

Appendix C Attachments & Sketches

METHOD STATEMENT TESTING AND COMMISSING PLAN 3 of 14

1.0 PURPOSE

• The purpose of this Method Statement Establishing various drinking water networks in the
governorates of the Qassim region.
• Implementing a water network (HPDE pipes) in the Qassim governorates. This procedure will
provide the necessary requirements and responsibilities related to the installation, inspection,
testing and operation of all facilities in the project.
2.0 SCOPE

2.1 The project is including the following items :

No Discription
1 110 MM ( HPDE )
2 160 MM ( HPDE )
3 200 MM ( HPDE )
4 250 MM ( HPDE )
5 Valve

2.2 This Tes ng, Commissioning and Comple on Plan has been developed according to
of review and testing in accordance with the contract dates for operation. The
stages are:
Stage 1 (Construction):
- ensure required forms have been submitted within required timeframes for each activity.
- ensure works are in accordance with the IFC design plans, relevant standards and
approved.
- ensure any proposed variation from the approved IFC drawings is to be submitted to NWC
review and acceptance request for information (RFI)
- A register RFI’s must be submitted with Red Line mark-ups.
- Ensure appropriate representatives are invited to all Factory Acceptance Testing and Site
Acceptance Testing
Stage 2 (Post Construction/Testing & Commissioning):
- Complete commissioning checklist as agreed.
- Checklists to be signed project manager and Maintenance team representatives
- Ensure items that require attention are identified and appropriate measures are put in
place for issues to be rectified.
Stage 3 (Completion/Handover):
- The project manager will arrange a `completion meeting’ consisting of a final walkover of
the works and any outstanding items identified at Commissioning.
- Delivered assets shall conform to the required quality as set out in the relevant
Specifications, codes and standards
- The O&M manual will be submitted to operations.
- Acceptance of the system will be as per the Handover checklist.

METHOD STATEMENT TESTING AND COMMISSING PLAN 4 of 14

3.0 DOCUMENT CONTROL

3.1 This project procedure is a controlled document as required by the Project Policy and issued
in accordance with the project procedure <Control of Documents and Data>.

3.2 Revisions of this document will be issued in accordance with the project procedure <Control
of Documents and Data> when the main text changes or when an appendix is added.
Revised appendices for substitution will be issued separately and, where appropriate, will
include a separate schedule of contents.

3.3 Document revision and appendix issue status are shown in the Project Register of
Management System Documents, a copy of which may be obtained from the QA/QC
Section upon request

4.0 DEFINITIONS, TERMS AND ABBREVIATIONS

MIR: Material Inspection Request

WIR: Work Inspection Request
NS: Inspection Checklist
SAC: Sectional Acceptance Certificate
PLTW: Pipe Leak Test for Water Mains
PM: Project Manager
SE: Site Engineer
CS: Chief Surveyor
WIR: Inspection Request
BOQ: Book of Quantities.
MIR: Material Inspection Request.
QA/QC: Quality Control / Quality Assurance.
QS: Quantity Surveyor.
MOS: Method of Statement

5.0 RESPONSIBILITY

5.1 The project manager has overall responsibility for the implementation of this project
procedure. Specific responsibilities have been assigned to members of the project
management team as described below.
5.2 Each NWC project supervisor through his civil execution team is responsible for executing
the as per the approved drawings and within the requested quality by the Contract.

5.3 The QC Manager is responsible for the preparation/reviewing of this procedure, its
amendment, controlled distribution and verifying proper implementation.

5.4 PROJECT HSSE STAFF

Responsible for monitoring and implementing safety matters such as work permits, first
aid and personal protection equipment Safety and traffic regulations are followed by all

METHOD STATEMENT TESTING AND COMMISSING PLAN 5 of 14

 workers during construction, in accordance with the approved project plan First aid boxes
are easily provided with a health and safety officer to ensure.

5.5 PROJECT SUPERVISOR / FOREMAN

Planning and obtaining the required manpower and resources in coordination with the
site engineer. Implement all activities on schedule to achieve targeted dates.
Coordinate with relevant work disciplines and contact the site engineer for daily activities.
Inform the discipline engineer regarding site inspections when ready.
5.6 PROJECT SURVEYOR AND QUANTITY SURVEYOR
Project surveyor is responsible for all kind of survey works and making of drawings.
Quantity Surveyor is responsible all kind of quantity measures and calculations.
5.7 PROJECT LABOUR
The work is carried out in accordance with the directions of supervisors/observers for all
activities in accordance with the planned schedule to achieve the goal. Coordination with
relevant work disciplines and communication with supervisors/observers for daily
activities. Make sure you do a task summary before you start working.

5.9 Contractor representative team for testing and commissioning :

N NAME POSITION COMPANY
1.0 Eng / Seif ELdin Ahmed Saleh Project Manager Dimension Accuracy Company
2.0 Eng / Seif ELdin Ahmed Saleh Technical Office Engineer Dimension Accuracy Company
3.0 Eng / MOHAMED REDA Site Engineer Dimension Accuracy Company
4.0 HESHAM Mohamed Surveyor Dimension Accuracy Company
5.0 Mohamed ABDELMOHSEN Saftey Engineer Dimension Accuracy Company
6.0 Mohand AShour Saftey Foreman Dimension Accuracy Company
7.0 Mohamed Essa Foreman Dimension Accuracy Company

5.10 Tools and Instruments to be used :

No Items
1 Observation Team
2 Pressure testing pump
3 Pressure Guage
4 Spare Parts Fitting ( different diameter )
5 Electric clamp meter
6 Weighing scale

METHOD STATEMENT TESTING AND COMMISSING PLAN 6 of 14

6.0 REFERENCES
o Project Quality Plan
o Project HSE Plan
o Project Control of Documents and Data
o Project Control of Inspection & Testing Procedure
o Project Control of Quality Records Procedure
o Contract Specification

7.0 Testing and Commissioning Work

7.1 Work Preparation.

7.1 Work Preparation.
 Arrange with NWC that where Contractor can start working according to Shop
drawings and Profiles.
 Contractor will arrange all permissions from government departments.
 Contractor will also provide enough safety barriers at site and arrange according to
safety instructions. Also arrange light safety for night.
 Contractor will also provide walking bridges for local people to cross the excavation.
And also provide steel plates at crossing of roads to cross light vehicles.

7.2 Work COMMISSIONING

7.2.1 GENERAL REQUIREMENTS
Flush all the pipe lines.
Make sure all the pipes' lines are pressure tested and leak free
All debris is removed from the basins and piping systems.
All equipment is filled with lubricant
All gates and valves are opened and closed and checked for smoothness of
operation and seating in the closed position.
7.2.2 CHECKS FOR THE INDIVIDUAL EQUIPMENT

7.2.2.1 Overhead Crane

 The thermal circuit breakers are set in accordance with the motor identification plate.
 Bearing lubrication.
 Incoming voltage: in accordance with the specifications on the electrical drawing.
 Test the operating of each sensor.
 Check the rotating way of the motor.
 Before getting started you need to control and adjust the limits switch.
 Bridge must be aligning properly all along the channel, guides wheel must avoid
misalignment.
 Control panel connected power.
METHOD STATEMENT TESTING AND COMMISSING PLAN 7 of 14
  Manual mode: check rotation of the scraper drive.
 Once the engine started, activate manually "Scraper up position switch" and "Scraper
down position switch" to ensure that it stops the motor.
 Manual mode: check rotation of the grid drive
 Once the engine started, activate manually "Home bridge position switch" and "Opposite
side limit switch" to ensure that it stops the motor.
 Set the switch "Scraper up position switch" and "Scraper down position switch"
 Set the switch" Home bridge position switch" and " Opposite side limit switch"
 Start li ing weight from 500kg and move crane all direc on.
 Again last test but with 1 ton weight.
 Again last test with full weight capacity of crane.

7.2 Work Execution

- Acceptance and rejection criteria are determined based on the contract and
specifications of NWC that depend on AASHTO (American Association of Highway and
Transportation Systems Standards).
Precedence of Materials and Testing Specifications
– All references to methods of testing or specifications of AASHTO, ASTM and others will
be deemed to refer to the latest methods of testing as specified in the Contract
Documents.
– Unless otherwise specified, AASHTO methods of sampling and testing shall be adopted
Where available.
 For Pipes and HC:
- All pressure pipelines shall be hydrostatically tested. They shall be tested in sections not
longer than 1 Km or as may be directed by the Supervisor.
- The Contractor shall submit to the Supervisor the hydrostatic test procedures for pipelines
and will stick thoroughly to what has been approved. The Contractor cannot start
hydrostatic tests before securing the Supervisor’s approval for the test procedure. The
procedure must mention the test equipment to be used, the testing method and criteria
for passing the test successfully, the water quality to be used, the method of flushing and
disposing of the test water.
- The Contractor shall give the Supervisor not less than 24 hours’ no ce of his inten on to
carry out a pressure test. Testing shall not commence without the Supervisor's approval.
- Before a length of pipeline is tested, each pipe shall be securely anchored. All thrust and
anchor blocks shall have been constructed and, the barrel of each pipe shall be backfilled
to the extent necessary to prevent flotation or movement of the pipeline and shall be not
less than 600mm above pipe crown. Joints shall be le exposed un l pressure tes ng has
been satisfactorily completed. Any need to Backfill a pipeline before pressure testing shall
not relieve the Contractor of his responsibility to excavate to locate and repair any leaks.
- Pressure testing shall be carried out as the work proceeds in such lengths as are convenient
but not exceeding 500 m. The ends of the length of pipeline under test shall be closed by
means of securely anchored caps or blank flanges. Pipeline valves shall not be used for this
purpose. All washout valves shall be fitted with blank flanges and the valves opened before
the commencement of any pressure test. At each air valve location, a special air release

METHOD STATEMENT TESTING AND COMMISSING PLAN 8 of 14

 arrangement shall be provided to allow manual release of air during filling operations.
Pressure testing shall not be carried out with permanent air valves in place.
- The pipeline to be tested shall be filled slowly with clean water in such a manner that all air
is expelled. Air vents shall be checked to ensure that no air is trapped at high points.
- As a guideline the following test procedures are described, the Contractor can propose
another test procedure if proved equivalent or superior to what follows and is approved by
the Supervisor.
 Test procedure:
The pressure in the pipeline shall be slowly raised to the working pressure of the line. The
test pump shall then be disconnected and the pipeline left under pressure with air valves
opened for a period of not less than 24 hours to allow air in the pipeline to be expelled and
pipe linings and pipe walls of absorbing materials to become saturated. At the end of this
period of time the air valves shall be closed and the test pump shall be reconnected and
the pressure in the pipeline raised to the test pressure as stated here below and this
pressure maintained for a period of 24 hours or such other period as directed by the
Supervisor.
Throughout this period the pressure in the pipeline shall not be allowed to fall or rise more
than 6m head of water below or above the test pressure and this shall be accomplished by
pumping water into or releasing water from the pipeline as required. The volume o water
pumped into or released from the pipeline shall be carefully measured. At the end of the
test period the pressure in the pipeline shall be adjusted to the test pressure by pumping
water into or releasing water from the pipeline as required.
The apparent leakage from the pipeline shall be ascertained from the net volume of water
that has been pumped into the pipeline during the test period.
The permissible loss shall not exceed 2 liters per meter nominal bore per kilometer length
per meter head per 24 hours.
The pressure shall be slowly raised by pumping to the required "Test Pressure". Pumping
shall then be discontinued, the pump disconnected, and the line kept under pressure for a
least 30 minutes. For the line to be accepted, the pressure shall not drop by more than 0.2
kg/cm2 during the said 30-minute period and there shall be no visible leaks at joints,
fittings, valves, etc. Should the drop of pressure exceed this value, the Contractor shall
search for the defects causing such pressure drop, shall make all necessary repairs and
repeat the test until the section under test meets the requirements. Provided always that
all visible leaks must be repaired whatever the loss of pressure.
Test pressure shall be as follows for both methods:
1) Test pressure shall be equal to 1.5 x Rated Working Pressure for pipeline working
pressure equal to or less than 10 kg/cm2,
2) Test pressure shall be equal to Rated Working Pressure + 5 kg/cm2 for pipeline working
pressures exceeding 10 kg/cm2.
During the pressure test exposed joints shall be inspected and any leaking or seeping joint shall be
remedied.
Test pressures shall be measured at the lowest part of the pipeline All signs of leakage shall be
remedied whether total apparent leakage from the pipeline under test is less than the apparent
allowable leakage or not. Should any length of pipeline fail to pass the pressure test the Contractor
shall at his own expense carry out all work necessary to locate and remedy the faults and to retest
the pipeline until it satisfactorily passes the test. A low-pressure air test (not exceeding 0.3 bar)
may be used as a preliminary joint tightness test prior to backfilling and hydrostatic testing.
METHOD STATEMENT TESTING AND COMMISSING PLAN 9 of 14
Contractor must flush the test water out no later than 24 hours a er successful completion of the
test.
 CLEANING AND DISINFICTION
After completion of pipeline hydrostatic test, Contractor shall carry out line disinfection before
system commissioning. Contractor shall submit the disinfection procedure to the Supervisor
clearly stating the type of equipment to be used, the method of flushing and disinfection, the
water quality used and how he intends to dispose of the flushing water. The Pipeline shall be
flushed clean prior to disinfection. Pipeline shall be flushed until flushing water is clean. One to
two volume of pipe is usually required for such flushing.
After closing all pipeline's outlets, the Contractor shall fill pipelines with clean water mixed with
chlorine at a concentra on of 20 mg per li er. A er a reac on period of 24 hours, the residual
chlorine shall be measured and a bacteriological test performed by taking a sample.

7.2 Work Inspection

ACCEPTANCE CRITERIA

This handover document sets out the requirements to be met for the project to be
handed over to operations following installation and/or construction. The Handover to
Operations Checklist will be used internally at completion to verify that the delivered
asset conforms to the intent of the design and is operationally complete.

ACCEPTANCE CRITERIA
DOCUMENTATION
Completable after
Item Description Checked Comments
Commissioning?
Yes No
All Project Objectives Met ☐ ☐ ☐
1 X hard copy (in folder) of all drawings,
manuals relating to equipment and tests to ☐ ☐ ☐
be left at site
A Structured electronic package containing
all as constructed information including ☐ ☐ ☐
drawing (PDF & CAD), manuals and

METHOD STATEMENT TESTING AND COMMISSING PLAN 10 of 14

 information relating to equipment and
testing
Electronic Plan Room Updated (as per
☐ ☐ ☐
above)
An electronic copy of the O&M manual and
a copy of Completion Certificate has been
☐ ☐ ☐
supplied to Maintenance team’s M&E Asset
Management Co-ordinator
As-built information in SWIFT
Including all old plans has been archived
☐ ☐ ☐
and all superseded plans has been removed
from site
All commissioning check lists complete ☐ ☐ ☐
Inspection checklist reports provided ☐ ☐ ☐
Certificate of electrical safety/Calibration
sheet for all instruments provided
Information on Watershed (Photos to be
☐ ☐ ☐
provided separated from Word Document)
Verify completion of Outstanding Item
☐ ☐ ☐
Register identified during Commissioning
Complete Comments/
Item
Yes/No/N/A Initials
Management/Documentation
1. Verify that all project objectives have been achieved.
2. Verify that all documentation has been provided:
3. As-Constructed Drawings (PDF & CAD, numbered and
named as per AM2488) and other design documents.
4. QA Documents (including ITPs, authority approvals,
electrical safety certificate etc.)
5. Photos (Construction, Final Asset and Defect
before/after).

8. Safety & Hazard Plan

8.1 Hazard Identification

a. Maintain a Material Safety Data Sheet (MSDS) for each chemical in the facility.
b. Make this information accessible to employees at all times in a language or formats that
are clearly understood by all affected personnel. Train employees on how to read and use
the MSDS.
Follow manufacturer’s MSDS instructions for handling hazardous chemicals.
d. Train employees about the risks of each hazardous chemical being used.
e. Provide spill clean-up kits in areas where chemicals are stored.
f. Have a written spill control plan.
METHOD STATEMENT TESTING AND COMMISSING PLAN 11 of 14
 g. Train employees to clean up spills, protect themselves and properly dispose of used
materials.
h. Provide proper personal protective equipment and enforce its use.
i. Store chemicals safely and securely.
j. For properly communication, there are for every 300 people’s one HSE professional with
full time.

8.2 Preventive Measures

8.2.1 Protective tools to be used
Requirements for the need of personal protective equipment (Also called
PPE).
Construction Common
Some sort of head gear. If there is a danger of falling objects, wear a hard hat.
If working in cold weather, wear a hat to keep the body warm.
Eye protection.
Wear safety glasses or goggles when pouring concrete. That way any
splashing concrete stays out of your eyes.
Gloves.
It makes common sense to protect our hands as much as possible. Wearing
gloves protects against scratches and cuts and possible infection because of
the chemicals used in concrete.
Long sleeve shirt/pants.
This keeps concrete from splashing on your body.
You can avoid burns that way.
Concrete Unusual
One vital piece of PPE is kneepads. Since concrete finishing often exposes
knees to additional wear and tear, it makes sense to wear kneepads designed
to take the stress rather than scraps of insulation held on by duct tape.
Rubber Boots.
If wet concrete comes into contact with the skin for any lengthy period of
time, we can get severe burns. Besides, it is easier to wash off rubber boots
than to wash off and have wet feet with regular boots after pouring mud.
Additional Discussion Notes:
Remember: Just like roofers have to wear a full body harness, concrete
workers need to protect themselves. Unlike roofers protecting against a fall,
we have to protect ourselves against additional wear and tear on our bodies.
8.2.2 Accident Preventive safety procedure.
 Pre-qualification of all equipment prior to the start of work.
 All personnel will be site trained.
 Method statement shall be discussed with all concerned.
METHOD STATEMENT TESTING AND COMMISSING PLAN 12 of 14
  Toolbox talks will be established and logged regularly.

9.0 Records

9.1 Inspection records generated by this procedure are to be managed in accordance with the
project procedure.
9.2 At the completion of works, the finalised completion documentation will be submitted to
NWC. Project documentation will include extracts from the specifications relevant for
commissioning and handover. It is intended that during the pre-commissioning and
commissioning stages that any ‘as-built’ changes are marked up on site and incorporated
and re-issued on the as-built drawing and project documentation.
The documentation will include the following:
• All drawings and As-built information in pdf and CAD formats
• Commissioning Checklists
• Testing results
• Inspection checklist reports
• O&M Manual including all manuals relating to civil, electrical, and mechanical equipment
and tests.
• A folder of construction photos

- - END OF TEXT - -

METHOD STATEMENT TESTING AND COMMISSING PLAN 13 of 14

 APPENDIX A
INSPECTION & TESTING PLAN

Title Reference Rev. Pages

Work Inspection WIR-001 001

APPENDIX B

Title Reference Rev. Pages

PMF-012-QUA-081_02
PMF-012-QUA-081 001 2
Inspection Test Plan

APPENDIX C
Attachments & Sketches

Title Reference Rev Pages

.
00
Shop Drawings attached …..

Profiles attached 00 …..

Generator Start-up Check lists attached 00 …..

Pump Start-up Check list attached 00 …..

METHOD STATEMENT TESTING AND COMMISSING PLAN 14 of 14