1. Underground Piping

1.1 Purpose:
To establish a systematic approach for the installation of underground piping systems in water and sewer treatment plant projects, ensuring proper alignment, connection, and functionality according to design specifications and safety standards.

1.2 Scope:
This work procedure applies to all personnel involved in the installation of underground piping, including site supervisors, pipefitters, welders, equipment operators, and construction managers.

1.3 Responsibilities:

• Site Supervisor: Oversees underground piping installation, ensuring adherence to plans, safety protocols, and quality standards.
• Pipefitters and Welders: Perform tasks related to pipe cutting, fitting, welding, and joint assembly.
• Equipment Operators: Operate excavators, trenchers, and other machinery for trenching and backfilling operations.
• Engineer: Verifies piping layout, alignment, and ensures compliance with design specifications.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

1.4 Materials and Equipment:

• Underground Piping (PVC, HDPE, ductile iron, etc.)
• Pipe fittings (elbows, tees, reducers, couplings)
• Welding equipment (if applicable)
• Excavators, trenchers, and backhoe loaders
• Pipe cutting and threading tools
• Survey equipment (for alignment and grade)
• Personal Protective Equipment (PPE) - helmets, gloves, boots, high-visibility vests

1.5 Procedure:

1.6 Preparation and Planning:

• Review piping layout drawings, plans, and specifications.
• Conduct a site survey to confirm underground piping routes and depths.
• Obtain necessary permits and approvals from relevant authorities.
• Coordinate with other trades and construction activities to avoid conflicts.

1.7 Excavation and Trenching:

1.8 Marking and Layout:

• Mark the alignment of underground piping routes on the ground.
• Use survey equipment to ensure accurate alignment and grade levels.

1.9 Excavation:

• Excavate trenches to the required depth and width using excavators or trenchers.
• Ensure trench dimensions allow for proper bedding and backfilling around pipes.

1.10 Pipe Handling and Installation:

1.11 Pipe Handling:

• Handle pipes carefully to prevent damage during transportation and installation.
• Use appropriate lifting equipment or manual handling techniques.

1.12 Pipe Installation:

• Place pipes in the trench according to the marked alignment and gradient.
• Ensure pipes are securely supported on the trench bottom and positioned for proper jointing.
• BluBox Installation: Ensure the BluBox system is assembled according to manufacturer’s specifications. Ensure system is installed level and securely anchored as required by manufactures specifications.
• Membrane Module Installation: Install membrane modules into designated tanks or racks. Follow precise alignment and spacing requirements as per installation manual. Verify proper sealing and connection of membranes.
• Piping and Valve Installation: Install inlet and outlet piping, as well as interconnecting piping between system components. Use appropriate fittings and ensure connections are leak-proof. Install valves and flow control devices according to system design. Verify Pipe Requirements: Before installing any piping, review the design/drawings to understand the required pipe size.
• Inspect the MBR/Bluebox: Visually inspect the MBR/Bluebox to confirm the actual pipe size present. Redundant Verification: Do not rely solely on design/drawings. Always perform a physical check to verify the pipe size.
• Documentation: Document your verification process, noting any discrepancies between the design/drawings and the actual pipe size.

1.13 Joint Assembly:

• Fit pipe joints using appropriate fittings (elbows, tees, couplings) as per design requirements.
• Apply lubricant or sealant on pipe threads or gaskets before assembly.

1.14 Welding (if applicable):

1.15 Preparation:

• Clean and prepare pipe ends and fittings for welding according to manufacturer recommendations.

1.16 Welding Process:

• Perform welding of pipe joints using approved welding procedures (if applicable).
• Ensure welds are inspected and comply with welding codes and standards.

1.17 Testing:

• Conduct non-destructive testing (NDT) as required to verify weld quality and integrity.

1.18 Backfilling and Compaction:

1.19 Bedding Material:

• Place and compact bedding material (sand or gravel) evenly around pipes to provide support and prevent pipe movement.

1.20 Backfilling:

• Backfill trenches in layers, compacting each layer to the specified density.
• Ensure backfill materials are free from rocks, debris, and other materials that could damage pipes.

1.21 Final Grade:

• Restore the ground surface to its original condition or as per landscaping requirements.

1.22 Pressure Testing (if applicable):

1.23 Testing Preparation:

• Fill installed piping system with water or air as per design specifications.

1.24 Testing Execution:

• Conduct pressure tests to ensure piping system integrity and leak-free operation.
• Monitor pressure levels and inspect joints for any signs of leakage.

1.25 Documentation:

• Record pressure test results and any corrective actions taken.
  Obtain approval from engineering or quality assurance for successful tests.

1.26 Safety Considerations:

• Ensure all personnel wear appropriate PPE at all times, especially when handling heavy equipment or working in trenches.
• Implement trench safety measures including trench boxes, shoring, and slope protection as per OSHA or local regulations.
• Conduct toolbox talks and safety briefings regularly to address specific hazards associated with underground piping installation.

1.27 Quality Control:

• Conduct visual inspections of installed pipes, joints, and fittings to ensure compliance with design specifications and standards.
• Perform dimensional checks and verify pipe alignment using survey equipment.
• Document all inspections, tests, and any deviations from the plan.

1.28 Reporting and Documentation:

• Maintain daily logs of underground piping installation activities, including equipment used, pipe lengths installed, and any incidents.
• Prepare progress reports and submit to the project manager or stakeholders.
• Keep records of all permits, test results, and inspections.

1.29 Approval:

Prepared by: George Bunker
Date: 07/03/2024

1.30 Note: This work procedure should be regularly reviewed and updated to reflect any changes in project requirements, equipment, or procedures. Adjustments may be necessary based on specific site conditions or unforeseen challenges encountered during underground piping installation.

2. Process Piping

2.1 Purpose:
To establish a systematic approach for the installation of process piping systems in water and sewer treatment plant projects, ensuring precise alignment, connection, and functionality according to design specifications and safety standards.

2.2 Scope:
This work procedure applies to all personnel involved in the installation of process piping, including site supervisors, pipefitters, welders, equipment operators, and construction managers.

2.3 Responsibilities:

• Site Supervisor: Oversees process piping installation, ensuring adherence to plans, safety protocols, and quality standards.
• Pipefitters and Welders: Perform tasks related to pipe cutting, fitting, welding, and joint assembly.
• Equipment Operators: Operate lifting equipment, cranes, and machinery for pipe handling and installation.
• Engineer: Verifies piping layout, alignment, and ensures compliance with process design requirements.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

2.4 Materials and Equipment:

• Process Piping (carbon steel, stainless steel, PVC, etc.)
• Pipe fittings (elbows, tees, reducers, flanges)
• Welding equipment (GTAW, SMAW, GMAW)
• Pipe cutting and threading tools
• Lifting equipment (cranes, hoists)
• Survey equipment (for layout and alignment)
• Personal Protective Equipment (PPE) - helmets, gloves, boots, safety glasses

2.5 Procedure:

2.6 Preparation and Planning:

• Review process piping isometric drawings, plans, and specifications.
• Conduct a site survey to confirm piping routes, elevations, and support requirements.
• Obtain necessary permits and approvals from relevant authorities.
• Coordinate with other trades and construction activities to ensure smooth workflow.

2.7 Pipe Routing and Support:

2.8 Routing Verification:

• Mark piping routes on the ground or structures according to isometric drawings.
  Use survey equipment to verify accurate alignment, slope, and elevations.

2.9 Support Installation:

• Install pipe supports (hangers, brackets, anchors) at designated intervals and locations.
• Ensure supports are securely fastened to structures and capable of bearing pipe weight.

2.10 Pipe Cutting and Preparation:

2.11 Cutting and Threading:

• Cut pipes to required lengths using pipe cutters or saws.
• Thread pipe ends as necessary for threaded connections, ensuring proper fit and seal.

2.12 Pipe Fitting and Assembly:

2.13 Fitting Selection:

• Select appropriate fittings (elbows, tees, reducers, flanges) based on design requirements.
• Ensure fittings match pipe material and size specifications.

2.14 Joint Assembly:

• Dry-fit or tack-weld fittings and pipes to verify fit-up and alignment.
• Complete final welding or assembly following approved welding procedures.

2.15 Welding Procedures:

2.16 Preparation:

• Clean and prepare pipe ends and fittings for welding according to welding procedures and specifications.

2.17 Welding Process:

• Perform welding operations using appropriate welding techniques (e.g., GTAW, SMAW, GMAW).
• Ensure welds are inspected and comply with welding codes and standards.

2.18 Testing:

• Conduct non-destructive testing (NDT) as required to verify weld quality and integrity.

2.19 Pressure Testing and Flushing:

2.20 Testing Preparation:

• Conduct hydrostatic or pneumatic pressure tests to ensure piping system integrity.
• Flush piping systems with clean water or air to remove debris and contaminants.

2.21 Testing Execution:

• Monitor pressure levels and inspect joints for any signs of leakage during pressure testing.
• Record test results and obtain approval from engineering or quality assurance.

2.22 Insulation and Coating (if applicable):

2.23 Insulation Application:

• Apply thermal or acoustic insulation to piping systems as specified in design requirements.
• Ensure insulation materials and installation methods meet project specifications.

2.24 Coating and Protection:

• Apply protective coatings (e.g., paint, corrosion-resistant coatings) to piping surfaces where required.
• Ensure coatings are applied evenly and inspected for uniformity and adhesion.

2.25 Final Installation and Documentation:

2.26 Final Installation Checks:

• Perform final checks to ensure all piping connections are tight, supports are secure, and systems are operational.
• Conduct visual inspections of installed piping to verify compliance with design specifications.

2.27 Documentation:

• Maintain comprehensive records of process piping installation activities, including material certifications, weld logs, and test results.
• Prepare as-built drawings reflecting any changes made during installation.

2.28 Safety Considerations:

• Ensure all personnel adhere to strict safety protocols and wear appropriate PPE throughout the installation process.
• Conduct toolbox talks and safety briefings regularly to address specific hazards associated with process piping installation.
• Monitor work areas for potential hazards and implement corrective actions promptly.

2.29 Approval:

• Prepared by: George Bunker
• Date: 07/03/2024

2.30 Note: This work procedure must be regularly reviewed and updated to reflect any changes in project requirements, equipment, or procedures. Adjustments may be necessary based on specific site conditions or unforeseen challenges encountered during process piping installation. Regular communication and coordination among all stakeholders are essential to ensure successful completion of the installation process.

3. Plumbing Systems

3.1 Purpose:
To establish guidelines for the installation of plumbing systems in water and sewer treatment plant projects, ensuring efficient, safe, and compliant installation according to design specifications and regulatory requirements.

3.2 Scope:
This work instruction applies to all personnel involved in the installation of plumbing systems, including site supervisors, plumbers, pipefitters, helpers, and construction managers.

3.3 Responsibilities:

• Site Supervisor: Oversees plumbing system installation, ensuring adherence to plans, safety protocols, and quality standards.
• Plumbers and Pipefitters: Perform tasks related to pipe cutting, fitting, assembly, and connection of plumbing fixtures.
• Helpers: Assist in handling materials, tools, and equipment during installation.
• Engineer: Verifies plumbing layout, design, and ensures compliance with building codes and standards.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

3.4 Materials and Equipment:

• Plumbing Pipes (PVC, CPVC, PEX, copper, etc.)
• Pipe fittings (elbows, tees, couplings, valves)
• Plumbing fixtures (sinks, toilets, faucets)
• Sealants, adhesives, and lubricants
• Pipe cutting and threading tools
• Pipe wrenches, pliers, and other hand tools
• Personal Protective Equipment (PPE) - helmets, gloves, boots, safety glasses

3.5 Procedure:

3.6 Preparation and Planning:

• Review plumbing drawings, plans, and specifications.
• Conduct a site survey to confirm plumbing fixture locations and routing.
• Obtain necessary permits and approvals from regulatory authorities.
• Coordinate with other trades and construction activities to prevent conflicts.

3.7 Pipe Routing and Installation:

3.8 Routing and Marking:

• Mark plumbing routes and locations of fixtures on walls or floors based on drawings.
• Use levels and measuring tools to ensure accurate alignment and placement.

3.9 Pipe Installation:

• Cut pipes to required lengths using pipe cutters or saws.
• Dry-fit or assemble pipes and fittings to ensure proper fit before final installation.
• Secure pipes with appropriate supports and fasteners, ensuring adequate slope for drainage as per design.

3.10 Pipe Connection and Fittings:

3.11 Fitting Selection:

• Select fittings (elbows, tees, couplings, valves) appropriate for pipe material and application.
• Ensure fittings are compatible with plumbing codes and standards.

3.12 Joint Assembly:

• Apply sealants, adhesives, or lubricants as needed for proper joint sealing.
• Tighten fittings securely using appropriate tools (pipe wrenches, pliers).

3.13 Fixture Installation:

3.14 Fixture Mounting:

• Install plumbing fixtures (sinks, toilets, faucets) securely to walls or floors.
• Connect fixtures to plumbing lines using approved connectors and fittings.

3.15 Testing:

• Conduct functional tests to ensure proper operation of fixtures (e.g., flushing toilets, running faucets).
• Check for leaks or malfunctions and make adjustments as necessary.

3.16 Pressure Testing (if applicable):

3.17 Testing Preparation:

• Conduct hydrostatic or pneumatic pressure tests on installed plumbing lines as required.
• Ensure all valves are closed and systems are pressurized according to design specifications.

3.18 Testing Execution:

• Monitor pressure levels and inspect joints and connections for leaks or pressure drops.
• Record test results and obtain approval from engineering or quality assurance.

3.19 Inspection and Quality Control:

3.20 Visual Inspection:

• Inspect all installed plumbing components for proper alignment, secure connections, and aesthetic appearance.

3.21 Dimensional Checks:

• Verify pipe diameters, lengths, and distances between fittings against design specifications.

3.22 Documentation:

• Maintain accurate records of plumbing installation activities, including material certifications, test reports, and inspection logs.

3.23 Final Cleanup and Commissioning:

3.24 Cleanup:

• Remove debris, excess materials, and tools from the work area.
• Ensure work areas are clean and free of hazards.

3.25 Commissioning:

• Assist in commissioning activities such as flushing lines, balancing systems, and ensuring proper functioning of all installed plumbing systems.

3.26 Safety Considerations:

• Ensure all personnel adhere to strict safety protocols and wear appropriate
• PPE throughout the installation process.
• Implement safety measures such as barricades, signage, and trench safety precautions as necessary.
• Conduct regular safety inspections and address any hazards promptly.

3.27 Approval and Review:

• Prepared by: [Name/Title]
• Date: [Date]

3.28 Note: This work procedure must be regularly reviewed and updated to reflect any changes in project requirements, equipment, or procedures. Adjustments may be necessary based on specific site conditions or unforeseen challenges encountered during process piping installation. Regular communication and coordination among all stakeholders are essential to ensure successful completion of the installation process.