METHOD STATEMENT FOR REINFORCE THERMOSETTING RESIN PIPE INSTALLATION..

METHOD OF STATEMENT

FOR ADHESIVE BONDED JOINTS and BUTT and WRAP LAMINATION JOINT OF REINFORCE THERMOSETTING RESIN...

1.0          PURPOSE

This method statement utilize to ensure that the assembly & installation of RTR (Fiberglass) piping work will be carried out safely, efficiently and in accordance with good working practice and as per Project specification. The instruction is intended to give general application guidance and establish controls during the preparation, fabrication, installation, testing and final acceptance of RTR (Fiberglass) piping work.

2.0        SCOPE OF WORK

The scope of this method statement is applicable to Non-Metallic U/G piping installation activities for RTR (Fiberglass) pipes which includes materials storage, handling, transportation, pipe laying & installation, pipe jointing such as Lamination, Taper/Taper adhesive bonded and Key-Lock type, inspection, testing and back filling procedure that to be installed on the Yanbu Export Refinery Project (YERP) EPC-3, Yanbu, KSA.

3.0             REFERENCE, STANDARD AND SPECIFICATION

3.1             Project Engineering Standards & Procedures

SPECIFICATION NO	DOCUMENT TITLE
SAES – A - 004	General Requirements for Pressure Testing
SAES – A - 007	Hydrostatic Testing Fluids and Lay-up Procedures
SAES – B - 017	Fire Water System Design
SAES – B - 067	Safety Identification and Safety Colours
SAES – L - 105	Piping Material Specification

SPECIFICATION NO	DOCUMENT TITLE
SAES – L - 610	Non Metallic Piping
SAES – L - 350	Construction of Plant Piping
SAES – L - 460	Pipeline Crossings Under Roads and Railroads
SAES – S - 070	Installation of Utility Piping Systems

3.2        Industry Standards &Codes

ASME B 31.3           Chemical Plants and Petroleum Refinery Piping

ASTM D 2855         Underground Installation of Fiber Glass (RTRP)

AWWA C 950              Fiber Glass Pressure Pipe

           

3.3Manufacturer Standards & Procedures

        

111-EP3-PU-G9L-9336       Bondstrand Installation, Operation & Maintenance Manual

111-EP3-PU-G9L-9350         Bandstand RTR (Fiberglass) Piping Field Hydro Test Procedure

3.4Piping Material Specification

PIPING CLASS	LINE SERVICE	BASIC MATERIAL
12FE0U2	FIRE WATER (FW)	RTR (Fiberglass)
12FE0U4	FRESH COOLING WATER (CW)	RTR (Fiberglass)
12FE0U6	OILY WATER SEWER (OWS)	RTR (Fiberglass)
12FE0U6	POTENTIALLY CONTAMINATED STORM WATER (PCS)	RTR (Fiberglass)

4.0MANPOWER, TOOLS AND EQUIPMENTS

4.1Manpower

            Project Manager                               Piping Superintendent / Supervisor

            Piping Engineer                                Civil Supervisor

            QC Manager / Supervisor                QC Inspector

            Safety Officer / Supervisor              Piping Foreman

            Surveyor                                            Pipe Fitter

            Crane Operator                                 Qualified Laminator

            Rigger                                                            Watchman / Helper

            Scaffold Erector                                Truck Driver

            Bonder                                                           Grinder

4.2       Tools and Equipments

Abrasive Cutting Disc                         Air Blower

Air compressor                                   PPEs (Safety helmet, hand gloves, Protective

clothing, goggles, dust masks, safety shoes, respirator, SCBA)

Air Relief Roller                                   Band clamp with puller rings

Drilling Machine                                  Exhaust fans

Engine Welding Machine                    Flapper-Wheel Sanders (Grit-60)

Grinder                                                Hydrostatic Test Pump / Filling Pump

Hacksaw                                             Paint Brush (4"wide) / Paint Roller

Hammer or Mallet                               Laminators Tool Set

            Slings                                                  Chain Block

            Measuring Tape                                  Power Generator

            Mechanical Pullers                             Tenting (Subject to weather conditions)

            Mobile Crane                                      Rubber Scraper Plate

            Non-Metallic Rope, Tag Line              Resin Mixer

            Pipe Shaving Tools                             Heating Blanket

            Pipe Support                                       Grinding Wheels

            Pipe vice                                             Shackles

            Power Drive                                        Lights (with posts)

            Pumps & Motors                                 Infra-Red Burner or Hot Air Gun

            Trailer Truck                                       Knife, File Abrasive Paper

            Ventilation Equipments                       Wrap-Around

            White Marker                                      Winch

5.0TERMS

            PMT                                                    Project Management Team

            Contractor                                         SAMSUNG Engineering Company Ltd.

            Subcontractor                                               Raymond Saudi Arabia Ltd.

6.0       RESPONSIBILITIES

6.1       Project Manger

Project Manager has the overall responsibility for this Method of Statement and is responsible for supporting it and for ensuring all entitles at the worksite actively participate. He is implementing, administer and provide oversight for the project Safe Work Plan Process.

6.2       Project Supervisor

Ensure the full implementation of this Method of Statement and identifies the requirements and add on resources for the effective accomplishment of the installation of underground piping. Ensure that hazard risk and mitigation measures determined during the project scheduling process are provided to the respective craft supervisory personnel responsible for safely performing the work.

6.3       Piping Superintendent/Supervisor

Ensure full compliance of all piping foreman, pipe fitters and labours regarding the execution of work in accordance with manufacturer’srecommendations and YERP requirements. Secure all necessary work permits. As a responsible Supervisor prior to assigning the work task performers, review any hazard, risk and mitigation and

measures determined during the scheduling process, visit task location, plan the work, analyze the work for any hazards and consider potential safeguards.

6.4       Piping Engineer

Provide technical support to site operation section, provide IFC drawings, specifications, piping test packages, standard and technical specifications. Responsible for PMT review of drawings and data and the resolution of technical work execution problems. Routinely review Safe Work Plan documentation submitted daily by respective Responsible Supervisor(s). Take an active leadership role in Safe Work Plan Process by verifying Responsible Supervisor(s) are properly conducting Safe Work Plan discussion meetings, routinely observe the Safe work Plan discussion meetings, routinely observe the Safe Work Plan Process in the field, activelyparticipate in the Safe Work Plan Process and regularly follow-up with observations of the actual work activity.

6.5       Safety Supervisor/Officer

Check the work area for any unsafe condition. Ensure that all safety requirements have been adequately addressed and the work is carried out safely in accordance with approved YERP Health Safety Environment (HSE) Safety Manual and Procedures. Ensure that material safety data sheets are available at site.

6.6       QC Manager / QC Supervisor

QC Manager is responsible for the implementation of all required quality controlled activities such as test and inspection for this particular job. QCSupervisor is responsible for coordination, carrying out of the inspection and testing details respective to this procedure. QC manager monitors the QC Personnel in their daily functions and conducts reviews of documentation and inspection/verification activities. Ensures adequately qualified and experienced QC Personnel are assigned to inspection duties. Identifies task related hazards and recommends to the Responsible Supervisor the work processes that could be used to ensure safe operation.

6.7       QC Inspector

Monitors daily piping activities and conducts inspections in accordance with the approved Project Quality Control Procedure, associated procedures and specifications. Prepares quality records and final acceptance documentation where required. Maintains close working relationship with PMT/Contractor/Subcontractor/Manufacturer Representative. Identifies task related hazards and recommends to the Responsible Supervisor the work processes that could be used to ensure safe operation.

7.0       SAFETY REQUIREMENTS

7.1       General

7.1.1 The main early preparation and any work shall be completely complied with respect to safety, Job Safety Analysis prior to execution of this particular job.

7.1.2 Necessary permits for all related activities within the construction site shall be obtained prior to the commencement of the job. Confined space permit shall be utilized prior to start of any U/G work activities. The confined space work shall be in accordance with the Confined Space Entry, Project Procedure - 833, and an approved Confined Space Procedure.

7.1.3 Unusual and unexpected acute hazard may be encountered while working inside the pipe, it is therefore required that all personnel who will be involved in this activity shall be oriented with nature of job and the hazards that might be countered. A confined space procedure shall be established as per approved safety plan as briefly outlined in this procedure.

7.1.4 Chemical waste such as resin, catalyst and styrene shall be disposed separately from other waste to prevent contamination of the surroundings as per the Project Procedure - 816, Waste Management and an approved Chemical Disposal Plan.

7.2       Safety Precautions

The chemical components required for butt & wrap joints present certain safety and health hazards if not handled well. Following are the recommendation:

7.2.1 Hazards

7.2.1.1      Resin: Liquid resin contains styrene which is flammable. Its vapours may cause irritation of the eyes, nose and throat. Excessive inhalation may cause dizziness, drowsiness or loss of consciousness.

7.2.1.2      Catalyst: Methyl ethyl ketone per oxide is a strong oxidizing agent and is a fire and explosion hazard. It is irritant to eyes, skin and mucous membranes, and is known as sensitizer. It shall always be stored in original containers & only small quantity shall be taken to the work place as per site activities/ requirement.

7.2.1.3      Solvent: (AP-62 or Methylene chloride) - The principal hazard is a loss of consciousness in case of excessive in halation of vapours. Exposure to high vapour concentration may cause cardiac irregularities.

7.2.2 Precautionary Measures:

7.2.2.1      Internal lamination shall be conducted in adequate ventilation. Workers shall wear dust / vapour mask while mainly working inside the pipe. All crew members shall use protective clothing (Long sleeved shirts, long pants), safety glasses and rubber gloves.

7.2.2.2      Ventilation is a necessity when lamination in confined areas because solvents tend to be heavier than air and migrate to lower levels. The fresh air inlet of the ventilation system shall be located near the top of the confined space, and the discharge should be located near the bottom, positioned to eliminate the dead air spaces.

7.2.2.3      Exhaust fans shall be used for ventilation. Suction side of the exhaust fan shall be kept on the top of the RTR (Fiberglas) branch tops and the discharge should be in the bottom portion of the pipe. Refer Figure - 1 at Safe Work Plan. Supplementary fans may be necessary to ensure good air circulation.

7.2.2.4      Tools should be correctly selected for the purpose, and also operated and maintained according to the manufacturer's instructions.

7.2.2.5      Suitable respirators shall be used if contaminant levels exceed Permissible Exposure Limits. Air-Purifying or Air-Fed respirators complying with an approved standard shall be used if a risk assessment indicates this is necessary. Respirator selection shall be based on the known or anticipated exposure levels, the hazards of the product and the safe working limits of the selected respirator.

7.2.2.6      Extreme care should be used if tools have the ability to create sparks in the presence of flammable vapours. "NO SMOKING" signs in all lamination material storage and working area shall be displayed.

7.2.2.7      Goggles and face shield shall be worn, while grinding to guard against flying particles and where necessary, hearing protection shall be provided to prevent long term hearing loss.

7.2.2.8      Solvent cements for    RTR are made from flammable liquids. These materials shall keep away from all source of ignition. Adequate ventilation shall be provided to reduce fire hazard and to minimize breathing of solvent vapours. Proper PPE shall be used to avoid contact of cement with skin and eyes.

7.3       Waste Disposal

7.3.1          To achieve and maintain environmentally sound practices for sanitation and for conservation of the environment, the Contractor has to monitor waste accumulation and to ensure prompt and correct disposal of the waste materials.

7.3.2          Non-hazardous wastes, hazardous waste and inert construction wastes at project site shall be segregated separately. The Contractor and Subcontractor HSE Personnel shall maintain a waste inventory to keep a record of the types and quantities of waste present at the job sites.

7.3.3          At any case theresin, hardener, solvent or any other chemical shall not be drained onto the ground or buried. Chemicals spills to the ground are to be remediated immediately. Thecontaminated soil along with the chemical spill waste shall be collected in a bin or container in the working area.

7.3.4          Waste materials shall be segregated at source by providing coloured and marked (with universal symbol and signage in Arabic and English) bins / containers the waste as follows:

7.3.4.1              Red     : Hazardous Wastes

7.3.4.2              Green              : Refuse

7.3.4.3              Brown              : Plastics

7.3.4.4              Blue                 : Glass

7.3.5          Sufficient quantities of bins / containers shall be placed for each type of waste at waste collections points, depending on the variety and quality of the wastes             expected from the location. There shall be effective and timely replacement of the    segregated bins and containers to the waste disposal area. Each bin / container shall have a tight sealing lid.

7.3.6      All waste generated on site shall be removed promptly to the central waste                        collection area, which shall be established by the Contractor and approved by                        LUBEREF.

8.0              MATERIALS

8.1              Provision

All RTR(Fiberglass) materials and components such as pipe, fittings, spool assemblies, lamination kits, resin catalyst and chemicals shall be supplied by Contractor in accordance with the specification AWWA C950, SAES-L-610, SAES-L-105 and manufacturer's recommendation.

8.2          Handling

8.2.1         Upon receipt of the RTR (Fiberglass) and other non-metallic materials shall be subjected to visual inspection for any damage during the transport and if there is any defect found, the same should be reported to the Contractor.

8.2.2         If load has shifted or indicates rough treatment, carefully inspection each pipe section for damage. Generally an exterior inspection will be sufficient to detect any damage.

8.2.3         Working tools, scaffolding or any other objects shall be prevented from striking or being dropped on or inside the pipe, fittings or spool assemblies.

8.2.4         Pipes, fittings and spool assemblies shall be lifted and positioned using proper rigging and hoisting practices. Lifting sling angle shall not be more than 45° from vertical.

8.2.5         Lifting sling that will be in direct contact with the pipe, spool assemblies and components shall be made from woven nylon or canvass and shall have minimum of 150 mm (6 inch) wide.

8.2.6         Lifting sling shall not be attached, or allowed to come into contact with nozzles, flanges, gussets or other fittings.

8.2.7         Pipes, fittings and spool assemblies shall be supported for storage on level ground in the original shipping or equivalent.

8.2.8         Loose RTR (Fiberglass) pipe shall be handled by hand or, if the pipe is too heavy, used nylon or cotton spreader slings.

8.2.9         Secure pipes and spool assemblies to prevent damage from wind and other contaminants.

8.2.10       In the storage area of RTR (Fiberglass) pipes and its components shall be visibly marked and barricaded to avoid accidents. Safety precautions must be ensured.

8.3          Storage

8.3.1         It is generally advantageous to store pipes on flat timber to facilitate placing and removal of lifting slings around the pipe.

8.3.2         Racks shall conform to factory shipping packages for each pipe size. Shelves shall be provided for continuous support of the pipe.

8.3.3         If loose pipes are stacked on each other, the stack height shall not exceed 1.5m adequate side support shall be provided to prevent slipping or rolling.

8.3.4         If pipe is stored on racks or bearing boards, the support shall be at least 75mm wide. Supports shall be spaced on 3 meter centers maximum with the first supports 1.5 meter from the end of the pipe.

8.3.5         All supporting surfaces shall be free of sharp objects.

8.3.6         Thermoplastic pipe tubing and fittings shall be stored under cover to avoid unnecessary dirt accumulation and long term exposure to sun light.

8.3.7         Thermoplastic pipe and fitting shall be stored with continuous support in straight, uncrossed bundles. Care should be taken in handling to ensure that unnecessary abuse such as abrasion on concrete or crushing is avoided.

8.3.8         Thermoplastic fittings shall be stored in their original containers. Fittings shall be stored in a building or under a cover that allows free air circulation.

8.3.9         Solvent cement and primer for thermoplastic piping shall be stored in an air-conditioned building with a maximum temperature of 26.7°C.

8.3.10       Gaskets, “O”-rings and locking keys shall be stored flat on racks below 38°Cand out of direct sunlight.

8.3.11       Adhesive for RTR (Fiberglass) piping shall be stored in an enclosure where temperature does not exceed 38°C.

8.3.12       Pipes and fittings shall properly protect from impact, especially on their ends. They shall not throw, bumped, hit or dragged and pushed over abrasive surfaces.

8.3.13       If the pipes are stacked in layers, inverted cradles or its equivalent shall be used on top of the pipe and the support cradles of various layers shall be aligned vertically. Stacking shall follow the requirements of pipe manufacturer.

8.3.14       Adhesive and solvent cement containers shall be tightly closed when not in use and shall be returned to the storage facilities to minimize exposure to excessive temperatures.

8.3.15       Solvent cement and primer for RTR (Fiberglass) piping shall not be stored if no expiration date is clearly marked on the container.

8.3.16       Lamination joint kits, resin, catalyst and chemicals shall be stored in the original packing in a dry place and within temperature and humidity limits recommended by material manufacturer.(Catalyst shall be stored in a cool maintained room(20-25C). Resin & Styrene shall be stored in a shelter/ stored area.)

8.3.17       Lamination joint kit shall be protected from dust, fog, water and other contaminants.  Materials that are damaged, expired, wetand in non-conformance with the material manufacturer and project standards shall not be used.

8.3.18        Resin, catalyst and chemicals shall be stored in the area approved by the safety department. It must be stored outside the working area and firefighting equipment shall be available within its vicinity. "NO SMOKING" or "FLAMABLE" signboards shall be visibly placed in that area.

8.3.19       RTR (Fiberglass) pipes shall have continuous support along its entire length when being transported by either truck or pipe trailer. All sharp edges that could touch the pipe shall be padded with sacks, rubber strips, or other suitable material.

8.3.20       Bearing boards at least 75 mm wide shall be used to protect RTR (Fiberglass) pipe from sharp objects on the truck beds. Rubber tire sections or other suitable material shall be attached to the bearing boards. Support spacing and height limits shall follow Para 10.3.1 to Para 10.3.5. Except that the end of support shall not be 1m from the ends of the pipe.

8.3.21       RTR (Fiberglass) pipe shall be secured with cotton or nylon strap.

8.3.22       Solvent cement primer and adhesive containers shall be protected from direct sunlight.

9.0              ASSEMBLY AND INSTALLATION

9.1              General

9.1.1      Checking drawings (IFC) as per latest revision.

9.1.2          Make sure that all RTR (Fiberglass)pipes, fittings and spool assemblies are free from defects prior to installation.

9.1.3          All safety permits required are obtained and precaution must be established.

9.1.4          The pipe installation shall be in the sequence of CW, PCS, OWS, FW and DW lines respectively.

9.1.5          The RTR (Fiberglass) pipe shall be kept near and parallel to the excavated trench within the minimum safe distance from the top edge of it.

9.1.6          Initially dewatering of the trench shall be done by the civil subcontractor, during installation of RTR (Fiberglass) pipes the dewatering shall be done by the mechanical subcontractor if necessary.

9.1.7          Before installing the pipes in the trench, the bedding's compaction and its testing shall be done.

9.1.8          Pipes shall be lifted by crane using 2 flexible nylon web slings at equal space. The lifting space shall be minimum 150 mm wide.

9.1.9          The elevation of pipe bedding has to be check as per IFC drawing prior to lying down of pipes.

9.1.10       Survey instrument shall be used to make sure that the laid pipes do not deviate from the established line. Pipe elevation shall be maintained in accordance to IFC plan and isometric drawings.

9.1.11       All reference points have to be certified and established for verification.

9.1.12       Pipe line shall be in a straight line both horizontal and perpendicular plane.

9.1.13       Pipes shall properly align and fit up as perfectly as possible. Best effort shall exert to eliminate the lateral offset. The maximum permissible lateral offset is 10 mm.

9.1.14       The curve of each pipe shall be within 10 mm of its theoretical position for line and level at each end.

9.1.15       Installation of scaffolding if necessary shall be done as an access to the joint preparation for fit up and external lamination, or for adhesive bonding of big diameter pipe.

9.1.16       Request and notice for closing of roads if necessary during RTR (Fiberglass) materials lay down and piping installation shall be done by subcontractor and approved by contractor safety department. The routing plan shall be made by the contractor safety department.

9.2          Pipe Laying Preparation and Installation

9.2.1          Ensure that all relevant documents and material have been approved by LUBEREF prior to commencement of the work, and that the latest revisions of IFC drawings, specifications including approved procedure are disseminated to concerned personnel who carry out the work.

9.2.2          Prior to commencing the installation work, any damage such as exterior scratch mark, impact mark, bulges, projections, blisters, indentation, delamination and/or abrupt           curvature of pipes, coupling and flanges shall be inspected visually.

9.2.3          Internal inspection shall also be performed to check for damage of inside surface, such as scratch or impact marks, and to verify drainage of water and removal of foreign materials.

9.2.4          Qualification for RTR (Fiberglass) piping installation personnel shall be trained and         qualified in accordance with RTR (Fiberglass) manufacturer's requirements.

9.2.5          All RTR (Fiberglass) fittings and spool assemblies shall be transferred to the working area nearer to the trench.

9.2.6          All RTR (Fiberglass) materials shall be handled in accordance with the manufacturer's recommendation.

9.2.7          Storage of RTR (Fiberglass) materials near the working    area shall also be considered to avoid being contacted with contaminants.

9.2.8          Damage components shall be marked and segregated and should not be brought in the vicinity of the working area.

9.2.9          Trench excavation and bedding details and procedure shall be in accordance withSAES-S-070 Para21 as follows.

9.2.9.1        The depth of the trench shall be dug deep enough to provide a minimum round cover above the top of the pipe, as required in Table 2 ofthis procedure, and a ground bedof at least 150mm in depth below the bottom of the pipe. The width of the trench should be wide enough to allow room for jointing, but in any case not less than shown in Table 1 of this procedure. Piping under road crossing shall be in accordance with the Project ProcedureSAES- L-460, Para 12.

9.2.9.2        The trench bottom shall be continuous, smooth, free of rocks, and to the line and grade shown on the installation drawings. The pipe shall have essentially continuous support and not rest on the joint. For RTR

                 (Fiberglass) piping, the trench contour shall not cause the joint angular deflection or the pipe bending radius to exceed the manufacture's limit.

9.2.9.3        The minimum trench width from the bottom to 300mm above the top of the pipe shall be as shown in Table 1.

TYPE OF PIPE	NOMINAL PIPE SIZE (mm)	MIN. WIDTH OF TRENCH (mm)
RTR (Fiberglass)	250 and under	O.D. + 300
RTR (Fiberglass)	300-600	2 x O.D.
RTR (Fiberglass)	Over 600	O.D. + 600

TABLE 1- TRENCH WIDTH

TYPE OF PIPE	NOMINAL PIPE SIZE AND SERVICE	MINIMUM COVER  (mm)
RTR (Fiberglass)	Under 150mm size	600
RTR (Fiberglass)	150mm and larger	900
Thermoplastic (CPVC)	Pressure pipe above 100mm	900

TABLE – MINIMUM COVER OVER THE TOP OF PIPE

9.3          Installation Activities

9.3.1         After lying the spools, place the sandbags beside of pipes to support from any movement.

9.3.2         These spool assemblies shall be the reference points in the installation of the underground cooling water supply and return lines.

9.3.3         After completing the laying of the initial spools, a dimensional check on the trench shall be done to ensure that the pipe length's measurement is correct including its fitting's location and that no interference from the pipe rack foundation existed.

9.3.4         After the dimensional checking and corrections was made, (if there is any) excavation on the pipe's joint portion shall be made prior to pipe laying works.

9.3.5         This excavated portion on the trench will be the working area of the laminators during jointing of big diameter pipe lamination or adhesive-bonding activity.

9.3.6         A 50-ton crane shall be used in these pipe laying activities in the working place. Therefore the pipes can be lowered only on the vacant or open area.

9.3.7         In this situation, rollers or carts shall be used to facilitate the laying down of the pipes in their respective locations.

9.3.8         Place the rollers or carts on the trench. Make sure that the vertical centre of the pipe and the roller/cart is identical. After checking the position of the rollers/carts, gently place the pipe on it.

9.3.9         Pull the pipe with the use of a chain block or lever block until it reaches the location.

9.3.10       With the use of chain block attached to the steel structure and to the nearest portion of pipe to be lifted, lift the affix portion of the pipe to remove the roller/cart. Use inspected "A" frame, if steel structure is not available.

10.0           ASSEMBLY INSTRUCTION AND PROCEDURE

10.1           Butt-and-Wrap Joint

10.1.1  Ensure that the gap between the two pipes to be laminated is within the allowable limit shown below:

10.1.1.1           2mm for diameter up to 300mm

10.1.1.2           3mm for diameter above 300 mm to 600mm

10.1.1.3           10mm for diameter above 600mm

10.1.2   Grinding the pipe surfaces (internal &external).

10.1.3       Prior to start of lamination work, check the temperature of materials and laminate surface. Temperature shall be within the range of 12°C to 38°C and minimum of 12°C above dew point.

10.1.4   Thoroughly clean the pipe ends that to be jointed.

10.1.5       Mark the plies width to be applied on the pipe joint (total bond width). This marked area to be grinded. Use rotary disc grinder/sander to grind the area. This procedure shall remove the shiny surface of pipe.

10.1.6       An internal lamination shall include groove at the lamination ends. This grooving shall absorb the laminating ply edges into it. These grooving facilitate the product flow without reducing the flow momentum.

10.1.7       The grinding procedure shall be repeated if the prepared surface area is contaminated prior to start of lamination work. Wipe the grind areas with clean solvent/cloth to remove the collected dust and any surface moisture. The solvent must be allowed to evaporate completely.

10.1.8       Align the pipe section as perfectly as possible. In case the gap cannot be avoided it shall be filled with "glass putty" cabosil powder mixed with catalyzed resin as per manufacturer's recommendation. The gap shall be no exceeding 10mm in width all around.

10.1.9       For the diameter 600mm and above, internal lamination is also required.

10.1.10    Each supplied joint kit contains the required number of plies chopped mat and    woven roving according to the manufacturer's specification.

10.1.11    Each layer consists of one or more sections to make up the complete around the           pipe circumference. These sections are pre-cut to a specific length that can be          handled easily. Re-check the applicable layers configuration from the process sheet provided.

10.1.12    The total number of plies is divided into layers with the same number of plies and           that each layer begins and ends with chopped mat plies.

10.1.13    Prepare enough resin for approximately 20 to 30 minutes gel time by adding proper amount of catalyst in the one gallon half cut plastic pot. Mixed the catalyzed resin through mixing tongue to make it homogeneous.

10.1.14    Cover the table with heavy craft paper and spread a thin layer of mixed resin on the      paper over an area large enough to include the largest piece of chopped mat. Lay a piece of chopped mat on the applied layer of resin on the table.

10.1.15    Dip the paint woolly roller into the resin (not very deeply) and apply it in the layer            mat smoothly all over the surface to wet-out well. Lay out a piece of woven roving over the wet mat and apply the paint roller over to it completewet out. (It is noted that the mat plies are always longer than woven roving so short of length in woven   roving shall be distributed equally over the mat.)

10.1.16    Continue building up by alternate mat and roving plies & wetting out each one     before applying the next one. Too many plies may not allow dissipation when the resin is under curing process and could cause blistering.

10.1.17    Apply a coating of catalyzed resin directly on the pipe joint ends through the same paint roller used for wet-out.

10.1.18    Lifts the resin impregnated plies through mixing stick from any corner & place them       at the pipe joint which is already grinded and well cleaned. Make sure that the wet    plies are placed centred& equally distributed on the pipe ends & the first chopped     strand mat lies directly on the pipe.

10.1.19    Roll out the paint roller over the plies to release big air cavities and any excessive           resin. Use steel grooved roller slightly pressed to remove out the air bubbles. The angle of groove roller shall be change time to time in order to remove the air bubbles in all directions. Make sure all bubbles have been taken out prior to start the plies to become hard.

10.1.20    Stop rolling as soon as the resin starts gel. Continue this procedure until all the    sections of the first layer been applied. Make sure that each section overlaps with the other by minimum 5cm.

10.1.21     Allow this lay-up round to cure & cool (until it is comfortable to touch with the barehands) prior to apply of another plies.

10.1.22    Complete the supplied number of plies application with the same procedure.

10.1.23    There could be another alternative to prepare the lay-up in place of on-work below:

10.1.23.1 It is to wet out the plies directly on the pipe joint itself one by one.

10.1.23.2 Spread a thin layer of resin directly on the pipe joint surface.

10.1.23.3 Pleased the chopped mat layer on the pipe joint with equal length both sides.

10.1.23.4 Wet out the layer through point roller.

10.1.23.5 Continue in the same manner as described earlier.

10.1.23.6 When working on the top section internally, a faster curing time is advisable. Increase slight amount of catalyst with a limit so that the bubble out process may end before gelling start.        

10.1.24    For internal lamination, the edges shall be penetrated into the previously made grooves at both side of the lay-up width to maintain smooth flow of the product during operation.

10.1.25    Approved Bonding Procedure Specification (BPS) shall be provided by QC section asper manufacturer qualification record.Manufacturer's standard procedure for all type of joints.

10.2           Cautions

10.2.1   Do not use resin if it is near gel.

10.2.2   Never allow solvent to run on uncured resin.

10.2.3   Each section of the pipe shall be laminated (at least partially) before   another length of pipe is added. This is to avoid excessive deformation   internally with laminated materials.

10.2.4   Provide sunshade to lower the ambient temperature in the joint area. If the ambient temperature is still above the required range, the work  shall be temporarily stopped.

10.2.5   Lamination works shall not be allowed during sand storms and high                         percent of humidity.

10.2.6   Resin shall be tested for gel time and peak exothermic temperature to                    determine and establish its curing characteristics.

10.2.7   Abraded area that is not covered with the overlay shall be coated with                    waxed resin after completion of joint overlays.

10.2.8   In case the lay-up joint is not completed by the end of the day, or the                      lamination process will be continued after several hours, following                            shall be taken.

1.    The shiny surface of the lay-up by minor grinding.

2.    Wipe the grinded area with clean solvent to remove the collected dust&allow the solvent to evaporate.

3.    If top layer of mat removed through grinding, an addition piece of mat shall be placed.

4.    Quality Control Inspection: The applied lamination standard shall be verified through QC Inspection

10.3           Butt-and-Wrap Joint

10.3.1 Dampness: The lay-up   joints   must   be   conducted   in   dry   Conditions.

Any moisture/dampness on the pipe surface or on the lay-up table may lead to a poor bonding of joints. Therefore, precautions must be taken during humid/wet weather. A portable shelter that will cover the pipe jointing area solves the purpose. A portable heat source (high volt bulb) may also require if weather is continuously humid or wet.

10.3.2Hot Weather: The gel time decreases as the atmospheric temperature increases and the gel time becomes very short. It is recommended to maintain the shelter over the pipe with adequate ventilation.

10.3.3 Cold Weather:lf the temperature at site is too cold which may increase the curing time of the applied layers, it is recommended to use the heated shelter. High voltage lamp/hot blowers could be used in the surrounding area, but not directly on the work place.

10.4    Taper/Taper Adhesive Bonded Joint

10.4.1      Only Qualified pipe assemblers shall carry out the work. Bonders shall be certified by the manufacturer, installation of piping as per approved bonding procedurespecification.     

10.4.2      Contaminated pipe surfaces shall be clean prior to machining the pipe ends.

10.4.3      When holding pipe in a vice, use rubber padding or similar material to protect it from damages. Scribe the pipe using a pipe fitter's wrap-around.

10.4.4      Use a hacksaw or an abrasive wheel to cut the pipes.

10.4.5      The pipes ends squareness shall remain within the tolerance. These tolerances can be checked by using the arbor of the pipe shaver which is inserted into the pipe base flush with the cut end of the pipe.

10.4.6      The pipe shall be adequately supported to prevent damage before fitting the arbor inside the pipe. Refer Figure-3. Fix the arbor to the inside of the pipe by turning the central tensioning bolt clockwise.

10.4.7      Adjust the shaver to the required pipe size. Be sure to use the correct Tapper   angle. (Various types of shavers are available for shaving the pipe ends, subject to the pipe size. Use the correct one.)

10.4.8      Shave the taper spigot. Maximum shaving depth / feed is 2mm. Repeat the shaving action until the required spigot diameter / spigot nose thickness is achieved.

10.4.9      Due to possible tolerance spreading the manufacturer recommends to use a nominal sized dummy bell end. This may avoid too long or too short assembly lengths. If the insertion depth in the dummy is too small, the spigot end to be shaved and to be adjusted.

10.4.10    Preparation of the surfaces to be bonded shall be within two (2) hours from assembly and if it lapses, the surface should be re-sanded.

10.4.11    The surface to be sanded shall be clean and dry prior to sanding.

10.4.12    Use 10-12 mm drill motor, 1700-2000 rpm and flapper type sander with 40-60 grit aluminum oxides abrasive.

10.4.13    The surface must have a dull, fresh finish and not a polished look after sanding.

10.4.14    The edges of the spigot shall slightly abrade.

10.4.15    Insertion depth of the spigot in the bell or coupling shall be marked on the pipe.

10.4.16    This marked shall be made to ensure proper alignment and full insertion of the bell and spigot.

10.4.17    Make sure that before mixing the adhesive, all preparations have been done and all parts to be bonded are ready for assembly, because mixed adhesive has a limited pot life subject to the ambient temperature.

10.4.18    Adhesive components shall be mixed until the mixture has a uniform colour and consistency.

10.4.19    Do not use adhesive mixture that begins to produce heat or lumps or gelled masses.

10.4.20    Adhesive shall not extrude into the bore of the pipe to the extent that a significant blockage is created. Extruded adhesive shall not exceed the lesser of 10mm or 5% of the pipe diameter.

10.4.21    If adhesive is not within 21 °C and 38°C range, which will need to warm   or cool it before mixing. The adhesive will not mix and spread well below 21°Cand will set up too fast above 38°C.

10.4.22    Bonding surface temperature shall be kept between 15°C and 40°C. Use shield or cover if the temperature is above 40°C.

10.4.23    All surfaces to be bonded (sanded area) must be completely covered with adhesive, approximately 0.5mm in the bell and 1mm on the spigot. Sufficient adhesive has to be applied on the cylindrical end of the spigot that will be covered by the bell.

10.4.24    When inserting the spigot in the bell pay attention to the marks and position and keep the joint together. Letting the spigot slip back or turning the spigot after complete insertion may result in a bad joint.

10.4.25    The bonded joint shall not be moved, vibrated or otherwise disturbed during curing time. Install the bond clamps on both components keeping sufficient space for the pullers (or winches) when pulling the joint together.

10.4.26    Pipe shall be assembled using mechanical pullers; care shall be taken to prevent the connections from being damaged during this operation. Theapplied tension using mechanical pullers shall be equal at both sides and in sequence to have proper alignment.

10.4.27    During the application of tension, it shall be ensured that there shall be no metal contacts with the RTR (Fiberglass) Pipe. Where required, rubber padding shall be provided as shown in Figure-2. It shall be necessary to set a bridge (piece of wood between puller cables and pipe outside) to simplify placing of the heating blanket.

10.4.28    After completion of bonding, the joint is allowed for ambient curing. Heat assisted curing is required for epoxy adhesive bonded connections, which shall be performed immediately after the adhesive mix is hardened. For the purpose of curing, the heating blanket shall be used.

10.4.29    Open end pipes shall be closed during curing to avoid of cooling down of inside surface of joint by draught. Also wind breaker shall be used when there is high velocity wind.

10.4.30    Only the required size of the heating blanket shall be used in the curing of the adhesive. Do not remove the pullers until the adhesive has fully cured.

10.4.31    If the temperature is below 10°C or the wind has a cooling effect, insulation material shall cover the heating blanket.

10.4.32    Insulation material should overlap the sides of the blanket with at least 100mm and should match to the pipe.

10.4.33    Functioning of the heating blanket shall be checked regularly. Temperature shall always meet the manufacturer's recommendation.

10.4.34    Time (start and end) shall be marked on the pipe to ensure complete curing.

10.4.35    During curing time, the joint shall not be moved, vibrated or otherwise disturbed.

10.4.36    Ends of pipe shall be covered completely to prevent ingress of foreign debris and contaminants.

10.4.37    In special cases, wherever the shaving and bonding a joint is highly difficult, there Butt-and-Wrap lamination type joint shall be considered as per the manufacturer standard.