SPC PDH /PP Project: Execution Plan For FRP Piping List of Contents

SPC PDH /PP PROJECT
Nasser S. Al Hajri Corporation

Jubail, Kingdom of Saudi Arabia
Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

Doc. No.NSH/WEP/FRP-01 Rev : 0
PIPING
LIST OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 RESPONSIBILITIES
5.0 FRP PIPING
5.1 MATERIAL
5.2 METHOD STATEMENT
5.3 PIPING ERECTION
5.4 INSTALLATION PROCEDURE
6.0 TESTING
6.1 HYDRO TEST
6.2 FLUSHING
6.3 SERVICE TEST
7.0 INSPECTION
8.0 BACKFILL
9.0 TOOLS & EQUIPMENT REQUIRED FOR FRP WORK
Doc PIP- 001 Page 1 of 18 Dept: Execution

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1. PURPOSE
To provide direction for the execution and construction activities of FRP piping
2. SCOPE
This procedure provides the activities involved in construction, work sequence, inspection
and testing activities, hauling, excavation, laying of pipe jointing, and backfill operations, for
FRP piping.
3. REFERENCES
ASME B31.3 Process piping
ASTM D-3839-89 Standard practice for underground installation of fiberglass pipe
ASTM D-2563-70 Standard practice for underground installation of fiberglass pipe
ANSI 16.5 Pipes, flanges and fittings
Project Engineering Specification for Piping Design SES H-101E REV. 3
Project Engineering Specification for Piping Material SES H-103E REV. 1
Project Engineering Specification Marking for Piping Material SES H-106E REV. 1
Project Construction Specification for Piping SES H-301E REV.4
Project Construction Specification for Piping inspection SES H-303E REV.2
Project Construction Specification for Testing piping SES H-317EV. 2
Project Specification for Site Preparation and Earth Work – SES- A- 301E
Project General Specification for Site Safety and Quality – SEP-C1-00/C7-002/003/ Q2-002
Related AFC Civil, Steel Structure and Piping Drawings.
4. RESPONSIBILITIES
4.1. Project Manager / Construction Manager :
The Project Manager/Construction manager is responsible for the implementation of this

procedure

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4.2. QA/QC Manager
QA/QC Manager is responsible to implement all required Quality Control/Activities for

the job
4.3. QA/QC Engineer
The Q.C, Q.A engineer is responsible for carrying out the inspection details in this
procedure
4.4. Piping supervisors
Piping supervisors will be responsible for the day to day construction activities and to
coordinate with safety department to ensure that safe working of personnel,
equipments and good house keeping.
FRP PIPING MAINLY AS FOLLOWS
 SEA WATER SUPPLY (OW),
 SEA WATER RETURN (OW),
SAFETY SHALL BE IN ACCORD WITH GENERAL PROJECT SPECIFICATION SEP –

C1-001 , SEP-C7-002
QUALITY SHALL BE IN ACCORD WITH GENERAL PROJECT SPECIFICATION SEP –

C7-003 , SEP-Q2-002
5. FRP PIPING EXECUTION
 SEA WATER PIPING
5.1. MATERIAL
Piping materials and its auxiliary materials to be used for the work shall be followed to SES
– H- 103E/106E Engineering specification for piping materials, Engineering specification for
marking of piping materials and lining work specification to be followed

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The details of FRP piping is given in Table A
TABLE A
1) Fluid : OW
2) Pipe Material : FRP
3) Size : 1/2” ~ 72”
4) TEST : Hydro- Pressure test ,

Service Test
5.2. METHOD STATEMENT
1) Pre-Excavation : Accordance with project specification for site preparation and Earth
work SES-A-301E pre-excavation shall be carried out.
Prior to starting any work, guard posts, railings, warning signs, watchmen service,
and/or any other safety devices shall be provided as required by State, and local
governmental codes and regulations and project standards as deemed necessary by
the owner. That will be maintained until work is complete. Job Hazard Analysis
reports shall be prepared and submitted.
Hazardous work permits for open flames, spark producing mechanical equipment
and potential explosive mixtures shall be taken in areas specified by the owner.
2) Initial opening survey to be done and staked out
a) Trench stakes shall be examined by the inspector to determine that they

have been properly located with respect to existing information. Increasing trench
widths to a dimension greater than that shown in the specifications will increase loads
on the pipe after backfill causing possible crushing or over-deflection. Maximum and
min trench widths are described in Specifications SES-A-301E.
b) Depending upon trench depth and soil stability, pipe may be placed near a
planned excavation to preclude damage to trench walls by heavy equipment. The
inspector is to guard against damage to pipe and trench walls.
3) Excavation
a) A minimum distance of 18 inch should be maintained between the trench wall

and adjacent underground piping, structures and foundations etc.

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b) Trenches should be mechanically excavated conforming to locations shown

on the drawing and to a grade elevation one-fourth the nominal pipe diameter
above the final invent.
c) If the earth being excavated provided suitable bedding material, hand or

machine excavation should continue to the final trench bottom.
d) If rocks, stumps, hard-pan, or other unyielding material is encountered, or if

unstable soil such as quicksand, gumbo, muck, peat, cinders, ashes, or similar
material is encountered, the excavation should be carried to a grade to a
excavation but not less than 4 inches below the bottom of the pipe..
e) A minimum of 4 inches of moist coarse sand, should be placed to provide a

satisfactory trench bottom by hand or mechanical tamping and to be compacted
as per ASTM std.D1557.
f) The trench bottom should be graded to a visibly smooth surface. Variations

such as pits. Depressions, humps, or raised surfaces in the final grade of the
trench bottom should be eliminated.
4) Bedding
a) Bedding material: The bedding material for trenches underneath pipes is to

be free of roots, organic material, debris or other deleterious materials and will
consist of clean sand. The base material is graded in accordance with
ANSI/ASTM C-135 within the following limit:
Sieve Size Percent Passing (By Weight)

1” 100
¾” 90-100
3/8” 40-100
No.4 40-100
No.8 25-40
No.8 18-33
No.30 5-15
No.50 0-7
No.200 0-3
b) Compacted granular bedding with carefully compacted backfill
c) Soil testing: The commonly accepted method for testing for compaction is
sand cone. (ASTM D-1556)

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5.3. PIPING ERECTION
1) Upon receipt the pipe shall be subjected for visual inspection for any damage during
transit, and if defects are found the same shall be intimated to SSA.
2) Guide ropes shall be attached to the pipes for unloading from the trailer.
3) Unitized packages of pipes shall be lifted as a bundle, if the load is not unitized only
single pipes will be lifted to avoid damage.
4) For handling the pipes only pliable slings, straps or ropes will be used.
5) Pipes will be supported with timber so as to enable removal of slings after placing it in
position.
6) All pipes will be chocked to prevent rolling.
7) If the pipes are to be stacked it will be ensured that it is stable in conditions such as
high winds, uneven areas or other horizontal loads. For pipes of diameter more than
1400 mm stacking will not be allowed.
8) Rubber ring gaskets if received separately will be stored in the shade in their original
packing and will not be exposed to sun.
9) It will be also protected from exposure to greases and oils, which are petroleum
derivatives, and from solvents and other deleterious substances.
10) Gasket lubricant will be carefully stored to prevent damage to the container.
11) As far as possible original shipping dunnage will be used when loading the truck and
if this is not available flat timber will be used to support the pipe. Pipes will be
chocked to maintain stability and separation. No pipes shall be allowed to contact
each other.
12) Pipes will be strapped to the vehicle over the support points using pliable straps or
rope.
13) Pipes shall be placed near the excavated trench leaving a minimum safe distance
from the top edge of it.
14) Survey instruments shall be used to make sure laid pipes do not deviate from the
established lines. Batter boards shall be located at both ends of trench and at
intermediate location, depending on length of trench. Pipe elevations shall be
maintained in accordance to plan and drawings.
15) Elevation, grades, lines must be referred to established, certified site bench marks.

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16) All piping materials shall be handled with adequate care so as not to produce any
adverse effects on pipe. Only synthetic slings to be used.
17) Pipes shall be aligned as perfectly as possible. Inspite of best efforts to align as close
as possible is not achieved and their exists a lateral offset, then this offset will be
equalized around the circumference of pipe maximum allowable gap between two
pipes after alignment shall be equal to the pipe wall thickness.
18) The lay-up joints will be fabricated in dry conditions since any dampness on the pipe
surface will cause a poor bond. Therefore a portable shelter that will fit around the will
assist in keeping water off the joint. A portable heat source should be used to dry the
pipe to be joined if dampness is present. The pipe and joint will be kept completely
dry until the joint has cured.
19) Joining pit location shall be checked and confirmed before laying of pipes.
20) Job Hazard Analysis shall be prepared (piping joining & cutting work).
WORK PROCEDURE FOR PIPE JOINING
Detailed work procedure for Lay-Up joint, Double bell joint and Flange joint are described here
with
I) LAY-UP JOINT (BUTT-WRAP JOINT)
1. Thoroughly clean all pipe ends that are to be joined with clean rags and clean solvent to
remove any build up of dirt or grease.
2. Immediately prior to joining, use a rotary disc sander to grind the surface of each pipe end
a distance of one-half the lay-up width. This procedure should will remove the shiny
surface of laminate, roughen the pipe surface and remove the remaining dirt for a good
joint. This procedure will be repeated if the prepared surface is contaminated prior to
fabrication of the lay-up. Contamination would include rain, mud, chemicals, wax, oil, dirt,
grease etc. It will be ensured that the material for lamination and laminate surface shall
be protected from dust, sand, fog, rain and other contaminants by covering the area
around the joint.
3. Wipe the ground areas with clean solvent and clean rags to remove the collected dust
and any surface moisture. The solvent must be allowed to evaporate completely which
takes about 5 minutes.
4. Align the pipe sections as perfectly as field condition will permit. Every effort shall be
made to butt the pieces together as close as possible.
In some instance a lateral offset (or “step”) may exist at the joint. This offset shall be
eliminated, if possible, by adjusting the alignment of the pipes. If the “step could not be
completely eliminated then it should be equalized around the circumference of the pipe.

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Note: The tolerance for gap and misalignment between the components shall be 1/3 of the
lesser component thickness.
After the alignment of pipe/spool with in the tolerance limit cab o sil filler is to be applied
between the gap of two components all around the pipe.
5. In general, joints are made by wetting out with catalyzed resin no more than five plies of
chopped mat and woven roving on one of the worktables and lifting these plies and
placing them on the pipe. Narrow layers of mat and woven roving are applied first,
followed by layers uniformly increasing the width. In this manner, the thickness of the joint
is the greatest in the vicinity of the seam and tapers to the edge of the plies.
6. Each joint kit shall contain the correct number of plies of glass required for the particular
job. Each layer will consist of one or more sections to make up the complete layer around
the pipe circumference. These sections are pre-cut to a length that can be handled with
out difficulty.
7. Review the applicable lay-up construction from the attached tables. Note that the total
number of plies required (20 plies) is divided into layers with approximately the same
number of plies and that no one layer contains more than 7 plies. Also that each layer
begins and ends with a ply of mat.
8. Prepare enough resin for 10 minutes use by adding the proper amount of catalyst by
volume to the resin in the 1-gallon plastic pots. Add more catalyst for a hot batch, if the
lay-up is for the bottom side of the joint. It will be ensured that the catalyst temperatures
are at a minimum 16 deg C before using.
9. Cover the worktable with heavy kraft paper. Spread a thin layer of catalyzed resin on the
paper over an area large enough to include the largest piece of mat or woven roving.
As an alternative to preparing the lay-up on the worktable is to wet out the lay-up material
directly on to the joint itself. Spread a thin layer of catalyzed resin directly on the prepared
pipe surface over an area large enough to include the largest piece of mat or woven
roving in the layer.
10. Lay a piece of chopped strand mats on the layer of resin and wet it out with the paint
roller. Continue building by alternating mat and woven roving as shown in the attached
tables and wetting out each one before applying the next ply. Make sure to center the
plies and never wet out more plies than what is called for in each layer. Too many plies
will not allow proper heat dissipation when the resin is curing and could cause blistering.
11. Roll out all air bubbles and excess resin from the lay-up with the grooved roller.
12. Apply a coating of catalyzed resin directly on the pipe where the lay-up is to be placed.
13. Center the lay-up on the pre-wetted pipe joint making sure the first chopped strand mat
lies directly on the pipe. Again roll out all the air bubbles with the roved roller. Cease
rolling at least as soon as the resin begins to gel.

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14. This procedure will be continued until all the sections of the first layer have been applied.
Make sure the sections overlap at lease five cm. The lay-up will be allowed to cure and
cool until it is comfortable to touch with the bare hand.
15. Continue using the same procedures with the remaining layers. Insure that the first and
last plies of the total lay-up are chopped strand mat.
16. Internal lamination shall not be applied for the pipes less than 36” in diameter.
Notes :
1. Do not use resin that is gelling. The lay-up cannot obtain full bond strength with gelling
resin.
2. Insure all solvent used to clean the pipe has completely evaporated before applying the
lay-up. The lay-up loses its bond if it is applied on a surface with solvent on it.
3. Never allow solvent to run on uncured resin.
4. If the lay-up is not properly bonded to the pipe, remove the lay-up and wash the area with
solvent, being careful not to run solvent into uncured lay-up areas.
5. During a period of rapidly changing temperature, pipes may move due to expansion or
contraction. This movement could reduce the bond strength of the initial lay-up plies, if
the plies have not cured prior to the movement. If this phenomenon is experienced. The
pipes must be restrained against movement while the lay-up joint is being fabricated by
means of hot patching at different locations over the circumference of pipe/spool.
Further it is to be ensured by the workforce that they do not perform the lamination on a
pipe, which is too hot, therefore in severe temperatures shaded area is to be provided
over the pipes/spools where the lamination is to be done.
6. When working on the bottom side of the joint, a faster gel time is desired. This can be
accomplished by 1) increasing the amount of catalyst (2 ½% maximum) and /or 2) using
the heat of a previous lay-up. Never place a lay-up over another lay-up if one is not
comfortable to touch with the bare hand.
7. In the event that a lay-up joint is not completed on the day it is started or if a layer of the
lay-up is allowed to cool for several hours, the following procedure should be followed.
a) Remove the glossy surface of the lay-up by grinding the lay-up area covered by resin.
b) Wipe the ground area with clean solvent to remove collected dust and allow the
solvent to evaporate completely.
c) Continue to apply the remaining layers of the lay-up, as previously described.

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Note : If the top layer of mat is removed when grinding, it will be necessary to apply an additional
piece of mat when the final layer or the lay-up is applied.
LARGE DIAMETER INTERNAL LAY-UP JOINT
Slightly different procedures and safety measures must be observed when making internal lay-up
joints on large diameter pipe. This section explains these differences and should be followed
explicitly.
A. POLICY
Unusual and unexpected acute hazards may be encountered while working within large diameter
pipe. For this reason, all personnel having cause to enter such a confined spec must exercise
proper safety precautions as outlined in this procedure.
B. RESPONSIBILITY
Responsibility for the safety of field welders rests with their immediate supervisor, this
responsibility includes:
a) Insuring that proper safety equipment is available, in good working order, and properly
utilized.
b) Insuring that employees under their control understand and comply with various safety
precautions as outlined herein.
C. HAZARDS
The hazards commonly encountered are:
a) Toxic vapors in significant concentrations.
b) Lack of oxygen.
c) Electric shock from portable lights, tools or associated electrical equipment.
d) Injury from mechanical equipment such as mixtures, conveyors etc.
e) Bodily injury from direct contact with corrosives or dermatitis-producing chemicals.
f) Physical hazards such as slipping, falling and falling object.
SAFETY REQUIREMENTS
Every attempt has been made to make the safety procedures established by these instructions as
complete as possible. However, there is no substitute for constand alertness and intelligent
planning in every confined space entry situation.

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In addition to rigid enforcement of the provisions of this regulation, it is essential that all persons
involved in each confined spec-entering job recognize the hazards involved and act accordingly.
Enforcement of minimum safeguards will under no circumstances be considered as relieving
those involved from responsibility for any unforeseen development or circumstance.
The following are minimum requirements for working inside large diameter pipe:
1. The field welding crew must consist of at least two people. Each individual is responsible for
complying with all safe work practices outlined herein and in to act as a “buddy” for co-workers
i.e., to insist that they also take necessary precautions and to assist them in the event of an
emergency.
2. A constant source of forced fresh air must at all times be provided. Air movement must be at
least 38 M/minute {i.e., at least cubic meter per minute through pipe}. Even with this amount
of air movement, respiratory protection may be required.
3. Each section of pipe is to be welded before another length of pipe is added so welders are
never more than one pipe length 17m from fresh air.
4. All lighting sources and power tools must be explosion proof and properly grounded.
INTERNAL LAY-UP JOINING PROCEDURES
1. The external portion of an internal joint will most probably be sealed through several means.
If an adhesive sealer is required, do not place the adhesive in the joint until the pipe is
lowered into the trench and is ready to be joined. This will prevent the adhesive sealer from
curing before the pipes are joined.
2. Large diameter pipe joint kits may contain one large strip and several short strips of the
proper widths of mat and woven roving for each ply required. The long strips are to be placed
in the pipe invert for internal joints or at the top of the pipe for external joints. The shorter
strips are then spaced evenly around the remaining circumference of the joint. The longer
strips will decrease the time required to make one joint, while the shorter strips will help when
working overhead. Make the strips overlap at least by 5 cm.
3. The lay-up strips can be wet-out right on the joint itself. Apply a coating of catalyzed resin
directly on the pipe for the first ply and roll out all air bubbles, wrinkles and excess resin as
described early. For internal lay-ups, extreme care should be taken in removing the
excessive fumes from inside the pipe.
4. It will require at least three people to make an overhead lay-up. A minimum of two persons
must hold up the lay-up while a third person rolls out all the air bubbles as described before.
The lay-up must be held in place until the resin begins to gel and sticks to material
underneath. When working on the topside internally a faster curing time is advisable. This is
achieved by slightly increasing the catalyst amount.

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II) DOUBLE BELL JOINT
1) Cleaning Coupling:
Double bell coupling grooves, center register groove and gasket rings shall be thoroughly
cleaned to make sure not dirt or oil is present.
2) Installing Gaskets:
The gaskets shall be inserted into the grooves leaving two to four uniform loops of rubber
extending out of the groove. There will be a minimum of one loop for each 450mm of
gasket ring circumference. Insert the rubber center register into the center groove.
3) Lubricating Gaskets:
With uniform pressure each loop of the rubber gasket will be pushed into the gasket
groove. Using a clean cloth a thin film of lubricant will be applied to the gaskets.
4) Cleaning and Lubricating Spigots:
Pipe spigots will be thoroughly cleaned to remove any dirt. Using a thin cloth a thin film of
lubricant will be applied to the spigots from the end of the pipe to the black positioning
stripe
5) Applying adhesive:
A generous layer of adhesive will be applied to the outside of the spigot and in addition a
thin layer of adhesive will be applied to the cut end of the pipe and to the bell. While
joining the excess adhesive on the spigot will be pushed to the outside and the adhesive
on the bell will be pushed inside leaving a small bead that protects the cut edge of the
pipe.
6) Joining the pipe:
The pipe to be connected will be brought near to the previous joint and the faces of the
bell and spigot will be made parallel. Two web slings will be wrapped around the two
pipes and the eye will be connected to the max puller which will be used to bring the
pipes together. While placing the puller sufficient packing will be given to avoid rubbing of
the puller with the pipe. Correct position of the edge of the coupling to the alignment
stripe will be checked to ensure both pipe ends are in contact with the center register.
III) Flange Joint (Bolting):
1) The Flange face and the ‘O’ ring groove will be thoroughly cleaned.
2) ‘O’ ring gasket will be checked for any damage.

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3) ‘O’ ring will be positioned and secured in the groove with small adhesive tapes.
4) Flanges will be aligned.
5) While mounting the flange the vertical and rotational alignment will be checked.
6) Bolts, nuts & washers will be inserted and will be tightened to the specified
torque value.
USE OF MATERIALS
The promoted resin included in the kit has a shelf life of several months. It is used by mixing it
with the appropriate amount of catalyst such a mixture will become warm through the exothermic
reaction and will progressively rise in temperature and reaction rate until it reaches a peak
temperature signifying an end to the reaction. The temperature peak is accompanied by a rapid
gelling of the material. It when sets as it cools to a hard mass. The gel time for the resin mixed
with approximately 1% catalyst is about 20 minutes at air temperature between 27 - 32C. Some
control of this gelling time is available through variation of the catalyst content. See the attached
resin information sheet for gel times of your resin at recommended catalyst levels and ambient air
temperatures. The minimum amount of catalyst gives a slow setting resin while a maximum
amount of catalyst given a “hot” quick-setting batch. The latter is desirable when working on the
bottom side of the joint to achieve a quick “stick-on” of the resin and materials. However, it calls
for quick work in getting the material flattened out and finished before it sets. The gel time
decreases as the ambient temperature increases. This property of the rsin in mixture can also be
beneficial when working on the bottom side of the pipe. The heat given off of one application can
help increase the reaction rate of a second application applied over it. The second applications
best applied when the first applications comfortable to touch with the bare hand but before it cools
to ambient temperature to gain the maximum benefit of the additional heat thus, the time
necessary for the second application to gel is reduced.
CAUTION SHOULD BE OBSERVED IN ALL CATALYZED RESIN BATCHES particularly “hot”

mixtures involving higher catalyst amounts. These release the heat of reaction more rapidly and
consequently peak at higher temperatures than the slower mixtures. In very “hot” batches,
ignition temperatures can be reached and due caution should be exercised in their use. Any pot
of reacting mixture or any which has been spilled which beings to smoke must immediately be
removed to a safe place where it will not do any damage if it ignites.
FIELD CONDITIONS
DAMPNESS:
The lay-up joint must be fabricated in dry conditions since any dampness on the pipe surface will
cause a poor bond. Therefore, precautions must be taken during wet weather. A portable shelter
that will fit around the pipe will assist in keeping water off the joint. A portable heat source should
be used to dry the pipe to be joined if dampness is present. The pipe and joint must be kept
completely dry until the joint has cured.

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HOT WEATHER WORK:
As mentioned earlier, the gel time decreases as the air temperature increases. In certain
situation, this property is beneficial. However, above ambient temperature of 38C the gel time is
very short. This will cause the resin to set before the air bubbles can be rolled out. Therefore,
joints should not be fabricated when ambient temperature above 38C are expected. When
working in direct sunlight above 27C, the work area should be shaded with a sun screen to allow
uniform working time and curing of the lay-up around the pipe.
In order to prevent the relative movement of pipe due to the thermal expansion and contraction
“HOT PATCH” is to be applied at different locations around the circumference of the pipe once
the pipe is aligned.
COLD WEATHER WORK
On the other hand, the gel time will increase as the air temperature decreases 16C is the
minimum outside air temperature that the resin, mixed with the proper amount of catalyst, will gel
in 2 reasonable length of time. If air temperatures at the job site are expected to be below 16 C
then a heated shelter will be required to bring the air temperature surrounding the joint above
16C . The temperature of the resin must also be kept above 16C in order for it to cure properly.
For making lay-ups in cold weather, it is recommended that drum heaters be used to keep the
resin at approximately 16C. The catalyst should be stored inside away from direct heat or
flames and maintained at approximately 16C along with the glass required for the lay-up. The
pipe in the area of the lay-up should be maintained at 16C. For this, an industrial heating
blanket used prior to making the lay-up should be effective. Other heat sources which can be
used include, hot air blowers or heat lamps. SALAMANDERS OR HEATERS WITH OPEN
FLAMES OR HEATING ELEMENTS ARE NOT RECOMMENDED FOR USE AROUND RESIN
MIXING, LAY-UP AREAS OR STORAGE AREAS.
During field jointing temperature of material, laminate surface and surrounding air shall be
maintained with in the range specified by manufacturer and as a minimum 2.5 degree above dew
point.
5.4. INSTALLATION PROCEDURE:
5.4.1 Under Ground Installation: For rigid joint U/G pipes the native must adequately
confine the pipe zone backfill to achieve proper pipe support.
5.4.2 Above Ground Installation On Supports: The line layout and supporting system
shall be done as per the final stress drawings. Care shall be taken not to alter
the support type and location.
The pipes and spools shall be kept in sequence as per the final isometric
drawing.
Above Ground Installation On Supports: The line layout and supporting system
5.4.3 Pipe Supports: The type of the pipe support shall be kept as per the final
isometric drawing based on the stress analysis results.

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5.4.4 Field Adjustment Length: Pipes shall be provided with an extra 25 to 100mm
length while fabricating the spool or the pipe. This extra length is generally
provided for flexibility.
6. TESTING
6.1. Hydro Test:
1) The line shall be tested in small segments
2) Inspect the completed installation to assure that all works has been finished
properly especially for pipe deflection, joints, system restrains, flange bolting
etc.
3) All laterals, stubs, accesses drops etc shall be capped or plugged and braced
against internal pressure.
4) All the valves and vents shall be kept open to avoid pressure surges due to air
expulsion.
5) Mount the pressure gauges such that it could be read easily.
6) Pressurize the line slowly.
7) Care will be taken not to exceed the test pressure
8) Holding time 30 minute and pressure to be recorded on a recorder at one end of

the test and a gauge at the other.
9) Inspection by Samsung and the owner if require)
10) Drain (water pump, water hose etc.)
Testing is carried out under conditions which allow effective inspection of the test length
and the joints in particular. For pipes laid in the ground this must be done before
backfilling. If the main is proved before backfilling, the trench is partially backfilled with
piles of soil deposited on the middle of every pipe to prevent any movement or disjoining
of the main. Block the ends of the test section with blank flanges equipped with valves for
water filling and air venting. Calculate the hydraulic forces developed at the ends of the
main and install a suitably sized restraining system. The forces are absorbed by timbers
laid across the trench or by sheet piling and adjustment is taken up on hydraulic jacks as
the line is compressed.
Hydro pressure test, service test, Hydrostatic Head Test shall be in accordance with
ANSI/ASME B31.3 Piping

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6.2. Flushing : of this system will be a pre-commissioning activity
6.3. Service Test:
1) Service test for a minimum of 30 minute, after completion of the installation
2) Service test shall be according to ASME B31.3 and project specification.
3) Inspection by Samsung and the owner if required
7. INSPECTION
1) Testing and Inspection :
The requirements for the inspection of underground piping systems are outlined
in ITP and witnessed by the owner. Test and inspection shall be in accordance
with Project specification for inspection of piping SES –H-305E, project
specification for site preparation and earth work SES-A-301E.
2) Excavation
a) Excavation inspection to be done as per SES-A-301E and shall be reported

as per ITP
b) Trench width/depth: To be inspected. as per Drawings and standards
c) Trench bottom : To be inspected so that over-excavation can be provided.

Over excavated material is to be replaced and compacted to provide a relatively
smooth and stable bed for the pipe. Rocks, stumps, and other unyielding
material are to be removed and replaced with well-compacted material.
d) Bedding: The foundation beneath and around the sides of the spring line of
the pipe is considered to be bedding. The degree of soil compaction to be tested
as described in the construction specifications for civil works.
3) Piping construction and inspection as per Project specification SES-H-303E
Material traces ability to be done set up inspection and recorded on
Pipe line location and elevation survey check and shall be recorded on
Material handling and storage
Edge preparation, Joining and welding

SPC PDH /PP PROJECT

PIPING
As built drawing with joint marking
Final acceptance of the joints shall be done after line check, punch list and
mechanical completion of the line.
8. BACKFILL
a) Initial Backfill: The inspector is to ensure that care is exercised in using

compacting equipment at the sides and directly above the pipe. Large impact
type compactors such as those used on backhoes may damage the pipe if the
force is too great and are not to be used without authorization by the owner’s
representative.
b) Excavation Backfill: The material between the top of the initial backfill and
finished grade is considered excavation backfill
c) Compaction Backfill: The inspector is to ensure that care is exercised in

using compacting equipment at the sides and directly above the pipe. Large
impact type compactors such as those used on backhoes may damage the pipe
if the force is too great and are not to be used without authorization by the
owner’s representative
d) Survey will check position of pipe before partial backfill
e) Shall be inspected to standard specification and project specification SES-A-

301E, and shall record as per ITP.
9. Tools & Equipment Required For FRP Connection
 Rotarty disc grinder

 Table to accommodate large strip of mat or woven roving
 Plastic bucket for mixing resin
 Graduated cylinder for measuring catalyst
 PI tape
 Masking tape
 Woolly rollers
 Cage for woolly rollers
 Steel rollers
 Paint brush
 Exhaust fans
 Air compressors

SPC PDH /PP PROJECT

PIPING
 Grinding discs
 Cutting discs
 Miracle point

SPC PDH /PP Project: Execution Plan For FRP Piping List of Contents

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SPC PDH /PP PROJECT

Nasser S. Al Hajri Corporation

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

5.0 FRP PIPING

5.2 METHOD STATEMENT

5.3 PIPING ERECTION

5.4 INSTALLATION PROCEDURE

6.1 HYDRO TEST

6.3 SERVICE TEST

9.0 TOOLS & EQUIPMENT REQUIRED FOR FRP WORK

Doc PIP- 001 Page 1 of 18 Dept: Execution

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

ASME B31.3 Process piping

ASTM D-3839-89 Standard practice for underground installation of fiberglass pipe

ASTM D-2563-70 Standard practice for underground installation of fiberglass pipe

ANSI 16.5 Pipes, flanges and fittings

Project Engineering Specification for Piping Design SES H-101E REV. 3

Project Engineering Specification for Piping Material SES H-103E REV. 1

Project Construction Specification for Piping SES H-301E REV.4

Project Construction Specification for Piping inspection SES H-303E REV.2

Project Construction Specification for Testing piping SES H-317EV. 2

Related AFC Civil, Steel Structure and Piping Drawings.

4.1. Project Manager / Construction Manager :

The Project Manager/Construction manager is responsible for the implementation of this

Doc PIP- 001 Page 2 of 18 Dept: Execution

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

4.2. QA/QC Manager

QA/QC Manager is responsible to implement all required Quality Control/Activities for

4.3. QA/QC Engineer

4.4. Piping supervisors

FRP PIPING MAINLY AS FOLLOWS

 SEA WATER SUPPLY (OW),

 SEA WATER RETURN (OW),

SAFETY SHALL BE IN ACCORD WITH GENERAL PROJECT SPECIFICATION SEP –

QUALITY SHALL BE IN ACCORD WITH GENERAL PROJECT SPECIFICATION SEP –

5. FRP PIPING EXECUTION

 SEA WATER PIPING

Doc PIP- 001 Page 3 of 18 Dept: Execution

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

The details of FRP piping is given in Table A

2) Pipe Material : FRP

3) Size : 1/2” ~ 72”

4) TEST : Hydro- Pressure test ,

5.2. METHOD STATEMENT

2) Initial opening survey to be done and staked out

a) Trench stakes shall be examined by the inspector to determine that they

a) A minimum distance of 18 inch should be maintained between the trench wall

Doc PIP- 001 Page 4 of 18 Dept: Execution

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20

b) Trenches should be mechanically excavated conforming to locations shown

c) If the earth being excavated provided suitable bedding material, hand or

d) If rocks, stumps, hard-pan, or other unyielding material is encountered, or if

e) A minimum of 4 inches of moist coarse sand, should be placed to provide a

f) The trench bottom should be graded to a visibly smooth surface. Variations

a) Bedding material: The bedding material for trenches underneath pipes is to

Sieve Size Percent Passing (By Weight)

b) Compacted granular bedding with carefully compacted backfill

Doc PIP- 001 Page 5 of 18 Dept: Execution

Job No.: SC0593Y EXECUTION PLAN FOR FRP Date: 14/04/20