Friday, 23 January 2009


QA-QUALITY ASSURANCE- Is the planning and organizing of system program to maintain a required level of quantity or reliability. This includes auditing the systems in operation and related controls to assure that they are being executed properly and functioning as expected.

QC - QUALITY CONTROL- Is a part of quality assurance   implements the letters by examining the physical characteristics and comparing them to established and acceptable quality and documents as stated in quality assurance program or plan.

ITP   - Inspection Test Plan mean the document sequences for quality activities in process,highlights the applicable quality and inspection criticality.

S -Surveillance:  QA/QC organization to monitor work in progress without notice of construction      organization.

W-Witness point:    QA/QC organization shall be notified   with the timing inspection in advance, however the inspection or test shall be performed as schedule if the QA/QC representative is not present.

H- Hold point:  QA/QC organization shall be notified of the timing of inspection on test in advance, inspectiontest shall not be carried out ,without the QA/QC organization representative in advance.

NCR- in case of violation of quality document by the contractor  NCR will be issued. The fulfillment or the required  corrective action will be mandatory by the contractor.

R- Review:  
* Documents review    =   Review
* Material receiving     =   Witness/Surveillance
* Installation and Testing     =Hold  Point


SAES-S-010 -Sanitary Sewers
SAES S 020  -Industrial Drainage and Sewers
SAES S  030-Storm Water Drainage System
SAES S  040-Water system
SAES S 050  - Sprinklers and Standpipe Systems in Buildings
SAES S 060 – Plumbing Code
SAES S 070 –Utility PipingSystem
SAES A 004  -General Requirements  for Pressure Testing
SAES B  017  -Fire Water System Design
SAES A  104-   Wastewater Treatments for Pressure Testing
SAES L 610  -Non Metallic Piping
SAES L 460 -    Pipe Line Crossing Under Road
SAES L 350  - Construction of Plant Piping
SAES L 1024  -Installation Piping Handing & Storage
SAES A 114  -Excavation and Backfill
SAES A  104- Wastewater Treatments for Pressure Testing
SAES L 1034  -RTR (fiber Glass) Pressure Pipe and Fittings
SAES L 1029 - RTR (fiber glass) Sewer Pipe and Fittings for Gravity Flow
SAES S 002   - Support Plastic Piping
SAES L 0012 - Non Sleeve Road Crossing for Pipelines
SAES L 0036 -Sleeve Crossing for Restrained Pipelines
SAES X400  -CathodicProtection of Buried Pipelines
SAES X 500 - CathodicProtection of Vessel and Tank internals
SAES X 600  -Cathodic Protection of Plant Facilities 
SAES S 1004 - Concrete thrust blocks, details of utility pipe
SAIC  S 4054-  RTR & Thermoplastic Pipe Installer Qualification
SAIC S 4055-  RTR and Thermoplastic Piping Receiving (Pressure and Sewer pipe)
SAIC S 4056– RTR and Thermoplastic Piping Handling, Storage  and Preservation
SAIC S 4057-  Assembly of Plastic (PVC,UPVC, CPVC and HDPE Piping
SAIC S 4058-  Assembly and Laying of RTR piping

GRP- Is the resistant corrosive effect of mixture with low concentration of acids,
 nearly neutral salts, solvents and  acoustic  substances, under both internal and
 external pressure.

GRE-Glassfiber Reinforced Epoxy
GRP-Glassfiber Reinforced Plastic
RTRP-Reinforced Thermosetting Resin Pipe ASTM D4024 reinforced without aggregate
RMRP  Reinforced Mortar Resin Pipe= a fiber glass w/ aggregate
HDPE- High Density Poly Ethylene Pipe
PVC-Poly Vinyl Chloride ASTM D1785
CPVC-ChlorinatedPoly Vinyl Chloride
DWV - Drain Waste and Vent

Typesof RTR/GREJoint.
1.Adhesive  Bondedjoint  and( EPOXY FIELD LAMINATION FOR BUILD UP)
2.Flange joint
3. Rubber Seal   joint
4. Butt / Lamination joint
5. Mechanical Coupler

1.   Gasketed Bell and Spigot
2.   Gasketed Bell and Bell Coupling for use for spigot End pipe

1.   Bell spigot ,Adhesive Bonded
2.   Butt and wrap w/ Reinforced Overlays
3.   Mechanical Joint Flange and Restrained GasketedJts.

1.   Tapered Bell and Spigot
2.   Straight Bell and Spigot
3.   Tapered bell and Straight Spigot
7.9 Adhesive and Solvent Cleaner  Shall be store at 38 C not less than 9 months from shipment.

PL- Plain End
CS- Cylindrical Spigot
TB- Tapered Bell
FF- Flat Face
E- Epoxy        
T- TensilS- Strength

RTR PIPE Material :
OILY WATER SEWER-     2 barg
FIRE WATER  17.5barg

25 mm     2.5 mm      50+50           30+301.9mm15/11
50mm      2.4 mm      50+50          30+302.4 mm20/14.7
80 mm     2.8 mm     50+5035+353.6 mm35/25.8
100 mm2.8 mm     50+50      35+353.6 mm45/33.1
150 mm    2.8 mm      50+50           40+40          4.1 mm40/29.5
200 mm    3.5 mm     60+60           60+60          4.4 mm80/59.0
250 mm     4.3 mm    75+75           60+60         4.8 mm85/62.6
300 mm      5.1 mm    90+90           70+70          5.6 mm130/95.8
350 mm    5.9 mm     105+105       80+80          6.6 mm180/132.7
400 mm     6.7 mm     120+120        90+90          7.4 mm185/136.4
450mm      7.5 mm      135+135        100+100       8.3 mm180/132.7
500 mm     8.3 mm      150+150        115+115       9.2 mm 175/129
600 mm       9.9 mm     180+180        135+135       11 mm255/165
700 mm     12.5mm       245+245          220/162.2
800mm                                                               320/236
900 mm                                                              335/247
1000mm                                                             365/269.2
1050 mm     18 mm     290+290                             378/278.7

Under Ground Bolt required ceramic Fluoropolymer coatedA307 GR. B, A563 GR.A with 2 washer
 .    300 mm distance from sewer to Potable Water
-       U/G Steel pipe material  ASTM A53, API 5L grade B

SAES S 010 Sanitary Sewers
SAES S 020 Industrial Drainage and Sewers
-       Air Gap minimum of 25 mm for the lip of drain Funnel not exceed 100mm
-       Pipe material RTR, Fittings RTR Wye Lateral
-       Pipe 150 to 450mm
-       Maximum surface travel of any liquid to catch basin shall not greater than 15 meters
-       5.5.3slope not less than 1:65 (1.5%)
-       5.7.3 The lip of drain funnel shall be elevated  80mm above the ground
-       5.9.5 Invert of the outlet shall be at least 25mm lower than the invert of the lowest 
incoming sewer in the manhole
-       5.10.1clean out as per standard drwg. Shall be provided 100mm(4 inch)
-       Vents 100 mm pipe diameter, shall be sloped to drain back to the manhole with low 
point. And required water tight in 4 hrs those back filled shall be tested in 24 hrs
SAES S 030 - Storm Water Drainage System
SAES S 040- Water System
-       UL/FM Approved (all valves)
-       UL- Underwriter Laboratories
-       FM- Factory Mutual 
-       NFPA- National fire Protection Association
-       NSF – National Sanitation Foundation

-       12LC0U Steel pipe ASTM A53, API5L Grade B
-       12FE0U RTR Fiber Glass
-       AWWA American Water Works Association C151 Cement Line with Coated
-       Non metallic pipe fittings CPVC, HDPE,RTRP
-       5.7.11 Flange Flat face/Full Face Gasket
SAES S 050Sprinkles and Stand Pipe System Buildings
 SEE Bracing Standards

UPS –Utility Piping System
UPC –Uniform Plumbing Code
AWWA C950  Fiber Glass Pressure pipe
Copper Tube for Piping required Type L
TYPE of Copper Joints
1.Composite Flange
2.Butt Welding
3. Socket Welding
4.Copper Nickel Capillary Bracing Fitting or Connectors

 IAPMO – International Association of Plumbing Official
 UPL – Uniform Plumbing Code
SOLVENT CEMENT shall be conform to the FF.
ASTM D2564- PVC to PVC
Plastic Pressure Pipe installed under any building floor, slab or cellar unless piping is fully encasedin concrete or protection of steel pipe
SAES S 070 - Installation of Utility Piping
a)   Potable  Water (Raw and Drinking Water)
b)   Raw/Fire Combined Water
c)   Dedicated Water system
d)   Sanitary Works
e)   Industrial drains and Sewers
PIPEmaterialif stored in rack or bearings board support at least 75 mm wide spaced or 3 meter and 1.5 m from the end of pipe.
10.7.3 Fire Water Lines and Piping with internal Pressure in excess of 200 PSI shall be required Woven Geotextile
12.1 Joints shall be restrained type (adhesive Bonded) Butt and Wrap Lamination Joints)
Mechanical type joints or unrestrained  typegasketed bell and Spigot Type Joints,
AWWAC950 sec.7.7These joint shall be assemble in accordance with the manufacture  procedure, Heating blanket shall be used to cure Adhesive bonded Joints.
12.3  Flat washer shall be use under nuts and bolt heads on non metallic flanges
17.2  Piping larger than 250 mm nominal pipe size shall be assemble in trench.
19.6 Requirements of pressure gauges, pressure recorder, calibration interval, calibration certificate shall be accordance with SAES A 004.
Field repair for RTR Piping shall be made in accordance with the pipe manufacture pre qualified repair procedure.

AIR BUBBLE (VOID) Not  to penetrate any surface limits apply to all surfaces, maximum
                Dimension 1-2 mmdiameter, 0.5mm thickness.
FOREIGN INCLUSION-Not penetrate any surface limits  apply to all surfaces, maximum depth 1mm
PIT  (pinhole) –Maximum depth 0.25 mm, maximum width 1.0 mm
POROSITY (pinhole)
SCRATCH –Maximum depth 0.40 mm not to exceed liner thickness
WORMHOLE (surface void)

Ø  Thermo plastic and RTR fittings shall be stored in their original containers. Fittings shall be stored in a building or under cover that allows free air circulation.
Ø  Solvent cement and primer for thermoplastic piping shall be stored in an air conditioned building with a maximum temperature of 25 C.
Ø  Adhesive for RTR piping shall be stored in an enclosure where temperatures do not exceed 38 C.
Ø  Gasket, O-rings and locking keys shall be stored flat on the racks below 38 C and out of direct sunlight
Ø  Training certificate (or proof of training) for installing RTR piping system must be obtained from RTR piping manufacturer. This certificate is valid for one year or the duration of the project, which ever is the first.
Ø  Hardness Test (BARCOL)--- 33 %  above ACCEPTANCE CRITERIA  at least 5 READINGS.
Ø  Mixed the Resin according to the recipe. The mixed ratio is 1 kg of resin is to 10 ml of hardener.

RTR Bonding Wrapping Joints Material
Resin mixed with IPD or
     Resin mixed with Easy Fit
WovenRoving orNon Woven Polyester Fiber (for wrapping butt joints)
Cabosil Powder ( for tacking and filling)
     Adhesive Cement or Easy fit Adhesive (for adhesive joint or for tacking butt jt.)
Non Woven Polyester Fiber
Glass veil surface mat (Top Tape)
CLEANING   using a clean cloth soaked in acetone.
CURING  for maximum chemical resistance, the product should be cured at 125 C for 1 hr.
16-5- Geotextile shall be used defending upon the soil condition to prevent soil wash away around the pipe

Ø  The test shall be  hydro tested at least 1.5 times the minimum design pressure of the piping system but not less than 150 psig for minimum two (2)  hrs.
Ø  Pressure gauge shall have range the test pressure with in the 30% to 80% of the full range (one month expirationfor calibration.
Ø  Test Manifold  shall be tested at least  1.2 times system of test pressure.
Ø  Sanitary and other gravity sewers (including oily water ) in which the internal pressure from static head and or friction does not exceed 103 kpa (15 psi)
Ø  Relief valve of adequate capacity set at 5% above at the test   pressure or a maximum of 170 kpa(25 psig) (onemonth expiration for calibration)  (16.5bar x5 shift %=+)=17.3
Ø  The test pressure shall be maintained for a minimum of 2 , maximum of 4 hrs.while the joints are inspected for leakage.
Ø  If for justifiable safety reasons the line must be backfilled, then the joints shall remain exposed during testing, otherwise the shall be a 24 hour recorded test.
  Records/ Reports Related to Quality                                                             
CAR-Corrective action report NCR- Non Conformance Report
STQ-Technical Query RequestPAF- Preventive Action  Form
FCR- Field Change ReportQCR- Quality Control Report
QCR-Quality Control Report RFI- Request for Inspection
ITP-Inspection Test PlanSSSS-Supplier Subcontractor Submittal Sheet                                  
MRI-Material Receiving Inspection QPQ- Quality Personal Qualification
MSS-Material Submission SheetWMS-Work Method Statement


ASME B31-1- Power Piping

Ø  Steam Power Generation
Ø  Co Generation Plant
Ø  Steam Generation Plant

ASME B31.3 – Process Piping

Ø  Refineries
Ø  Petro chemical
Ø  Pump station within the plot limit of refinery or petrochemical plant
Ø  Designated pipe ways or corridors with in process piping facility
Ø  Steam generating facility with in the process piping
Ø  Tank farm with in facility designated in process piping
Ø  Terminals for transporting and shipping crude oil and its derivatives
Ø  Shop fabrication skid mounted piping such as metering skid and corrosion inhibitor injection skid

ASME B31.4 – Pipe line transportation system for liquid Hydrocarbon and other liquid

ASME –B1.20.1-Pipe Threads General purpose

ASME B16.5  - Pipe Flange and Flange fittings

ASME  B31.8- Gas Transmission and distribution Piping System

ASME 1X- Boiler and Pressure Vessel

NACE –National Association of Corrosion Engineers

ASME –American  Society  of Mechanical Engineers

ASTM- American Society of Testing Materials

ASNT- American Society of Nondestructive Testing

API- American Petroleum Institute

MSS –Manufactures Standard razation Society of Valve

AWWA- American Water works Association

AWS – American Welding Society


SAES    A   004  General Requirement for Pressure Testing
SAES    A 007  Hydrostatic Testing fluid and Layup Procedure
SAES    L  109  Selection of Pipe Flanges Stud bolt and Gasket
SAES    L   110   Limitation on Pipe Joints and Components
SAES    L   120Piping Flexibility Analysis
SAES    L 150Pressure Testing of Plant Piping and Pipe Lines
SAES    L  310 Design of Plant Piping
SAES    L  351 Bolted Flange Assembly
SAES    L  460 Pipeline Crossing Under roads and Railroads
SAES    L   420Scraper Trap Station Appurtenances
SAES    L   100Applicable Codes and Standard for Pressure 
SAES    L   133Corrosion  Protection Requirement
SAES  L   315Steam Tracing and Jacketed Pipe
SAES   L   440   Anchors for Buried Pipe lines
SAES    L105Piping Class and Material Spec
SAES    L 125  Safety Instruction Sheet for Piping and Pipe Lines
SAES   L   350  Construction of Plant Piping
SAES    L   450 Construction on land Near Shore Pipe line
SAES    L   108  Selection of Valve
SAES    L   130  Material for Low Temperature Service
SAES    L   140 Thermal Expansion Relief in Piping
SAES    L   351  Bolted flange Assembly
SAES-   L   109 Selection of Pipe Flange, Stud Bolts and Gasket
SAES    L   131 Fracture Control of Carbon Steel Line Pipe
SAES    L   410  Design of  Pipe Lines
SAES    L   610Non Metallic Piping
SAES    A  206    PMI for Alloy and Stainless Material

Utility Identification

1.   Fire Water
2.   Service water
3.   Cooling Water
4.   Demi water
5.   HP Steam
6.   LP Steam
7.   MP Steam
8.   HP Condensate
9.   MP Condensate
10. LP Condensate
11. BFW
12. Plant Air
13. Instrument air
14  Fire Water
15  Service water
16  Cooling Water
17  Demi water
18  HP Steam
19  LP Steam
20  MP Steam
21  HP Condensate
22  MP Condensate
23  LP Condensate
24  BFW
25  Plant Air
26  Instrument air
27  LP Nitrogen
28 LP Flare

Utility System:
 S   TEAM 
          W ATER      

                                               INSPECTION ACTIVITES:

1.   Iso Drawing  – Is an easy method of drawing image, all vertical line are drawn verticality
but all  horizontal line are drawn in 30 deg to the base line.
2.   P&ID – Is an schematic illustration of piping instrumentation and system equipment

3.   Test Package Contents:
1    Review of test package preparation
2    Pressure test Diagram
3    Test legend and symbols
4    Drawing Index (P&ID and Iso Drawing)
5    Verification of testing Equipment &Preparation
6    Pre Test Punch list
7    P& ID
8    Isometric  Drawing with weld map
9    Line history reports ( joint log sheet)
10  Compaction test Report (U/G)
11  Survey report
12  Internal cleaning /air blowing Report
13  Test calibration Certificates (test manifold, gauges, recorder, PZV)
14  Water analysis report
15  Pressure Test and visual inspection report
16  Depressurization & disposal of Hydro Test
17  Flange  face , Gasket verification ,Bolt tightening report
18  Re-instatement Inspection
19  Safety Instruction Sheet
20  NDT Report (PT, MT,RT,PWHT, PMI,Hardness test)

   4.Bolt Tightening and Tensioning Inspection(RFI)
Check the FF:
·         Flange serration and Gasket Verification  (class and type)
Damage Criteria for Flange Raised Face:
See SAIC -L -2002
·         Flange Alignment, Tilt 1.6mm,2.4 bolt hole acceptable tolerance
·         Bolt and nuts material, color code and stencil,
·         Tightening Sequence
·         Check the torque value
·         Torque wrench certificate
·         Bolt tightening group approved w/ ID

(Torque Ratio=1 : 185 )
EX:  1” 3/8 -B7m Coated ft/lb
30%=320 devidedto 18.5=17.29ft/lb to be set in small torque wrench
100%= 1067 devidedto 18.5= 57.7 ft/lb  to be set in small torque wrench
B7 –Process and General Services
L7/L7M- Low Temp Services
B16 – Upper Intermediate Temp sevices
B7M/L7M- Wet Sour Services
Ceramic Fluor polymers Coated Bolts- Under Ground Piping
Torque value SEE: SAIC-L-2001
ASME  B31.3  sec 335.2.3 Bolt Length- Bolts should extend completely 
through their nuts.
Any which fail to do so are considered acceptably engaged if the lack of 
complete engagement is not more than one thread.

5.Fit/Up  Inspection(RFI)
Check the FF:
·         3mm clearance for  Butt, 1.5 for socket Joint Clearance,
·         Material class, sched ,and code no. as per drawing
·         Color coding,
·         Heat no.
·         Square, Level, Plumb and Dimension
·         Orientation as per Drawing
·         Internal Pipe Cleaning
Pipe- Identified by NB and Thickness is defined by Schedule based on 
ANSI B31.3
Tube- Identified by OD
Eccentric Reducer (Suction) To avoid cavitations to maintain  Elev. (BOP)
in rack
Concentric Reducer  ( Discharge) Vertical pipe line
Vent hole – For venting of hot gas which may get generated to welding
(Test pressure 175kpa= 17 barg)

6.Valve Installation Inspection(RFI)
Check the FF:
·         Material Class as per Drawing
·         Flange Face serration inspection
·         Flange face Coating
·         Color Coding
·         Valve Handle Orientation
·         Flow Direction (if required)
NOTE:  SAES  L 108
4.7.1 Field Testing  Butt wel and socket end valves in nominal
 pipe size (NPS) 2
 inches  and smaller are excemp inches  and smaller are exempt 
from  the above
field testing requirements.
Test Holding Time 1 minute., 900 class and high pressure shall
 be test in min 5 min.
And no visible leakage.
NPS  2” and smaller all ratings- 10%
NPS 14 NPS and less than ASME  600  -25%
NPS 14” and above -        100 %
2” and  ANSI class 600 – 100 %
2” and API rating 2000 psi above – 100%

   7.Weldolet  Installation and Branch Connection (RFI)
·         Material Class as per drawing
·         STUB IN  or  OUT
·         Clearance, Dimension

    8. Pump Flange Alignment  .20 mm Tilt(RFI)
    9. PZV  to Pipe Flange  Connection Alignment   1.6 mm Tilt(RFI)
   10. Orifice Flange Inspection  (RFI)
               Check The FF:

·         Flange face serration inspection

·         Check the material class, size and code as per drawing
·         Tilt acceptable tolerance
·         2.4 mm for bolt hole or free
·         Orifice Flange Internal smooth Grinding
·         Jack bolt and orifice tap orientation

    11.Material Inspection (RFI)
Check the FF:
·         Manufacture and Vendor approved by company
·         Material approved by company
·         Mill test Cert. with signed by 3rd party
·         Color Coding ,
·         NDE Report with signed by 3rd party
·         Test Report  with signed by 3rd party
·         Heat no.
·         Visual Inspection

     12.  Spool Released Inspection (FAB Shop)(RFI)
Check the FF;
·         As per ISO Drawing
·         NDT Report acceptable

     13. Pre installation  Inspection ,Air Blowing , Pipe end Capping(RFI)

     14.Valve testing Inspection as per Project Required Percentage.(RFI)

15. Hydro testing  Inspection(RFI)
Check The FF:
·         Test Package signed prior for test, All cert. shall be attached in
 test package a
·         (punch “A” should be closed)
·         Hydro Test Manifold with Tag  and  Certificate.
·         Hydro test Manifold x1.2 test pressurewith certificate
·         Relief Valve  plus 5% of  test  Pressurecheck the certificate 
validity of 1 week
·         Pressure gauge  Range 30%-80% (1 barg=14.5 psi)check the
 certificate 1 month validity
·         2 or 3 Pressure Gauge shall be installed
·         Safety Permit
·         Line Design pressure X 1.5 = Test pressure
·         Check the Barricade Tools and Equipment
·         30 min Holding  Time
·         Check the  temporary blind  thickness is suitable as the
 test pressure
·         Vent should be installed in highest point and shall be open 
during filling of water.

E8018 defines:
E – Electode
80 – Tensile Stregnth (psi x 1000)
1 – Positional Capabilities
8 – Flux  coating & Electrical Characteristic

SMAW- Shielded Metal Arc Welding  (DCRP-  Direct Current Reverse Polarity)
GTAW- Gas Tungsten Arc welding – ( DCSP – Direct Current Straight Polarity)
GMAW- Gas Metal Arc Welding
SAW- Submerge Arc Welding
FCAW-Flux Cored Arc Welding
NDT- Non Destructive Test
PWHT- Post Weld Heat Treatment
PT-Penetrate  Test (Cleaner, Penetrate, Developer)
RT- Radiography Test
MT – Magnetic Test
PMI-Positive Material Identification
UT- Ultrasonic Test
Hardness Test-

                                        LUBEREF ARAMCO
CS, LTCS, SS, DSS- Butt Weld  fittings – ASME B16.9
CS, LTCS, SS, DSS- Socket Welding Threaded Fittings  ASME  B 16.11
150,300,600 Raised Face , 150 may also flat faced
900,1500,2500  Gasket groove type
SPIRAL WOUND  Gasket  ASME B16.20        SAES   L 109
NON  METALLIC  Gasket  ASME B16.21
RING JOINT  Gasket   ASME B16.20
CHECK VALVE -1/2- 1 ½- BS-EN-ISO-17292
BALL VALVE- 2” ~   - 04 -SAMMS-051
PLUG VALVE (lubricate) -04 -SAMMS -053
BUTTERFLY VALVE  High Performance – 04 –SAMMS-047
General Requirements for Valves - 04 –SAMMS- 035
Valves Inspection  and Testing -04 –SAMMS-048
CG  - A53  Hot dip galvanized. 
FE  - GRE U/G pipe
CC- Carbon
CC – 05-07  Nace
CJ -  Alloy
SD – Stainless steel
SX- Duplex (NACE)

Prepared by M.Ajmal Khan


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