Packing, Handling, Storage & Preservation Procedures

Vendor Future Pipe Industries – SAUDI ARABIA

Client NAIZAK GLOBAL ENGINEERING SYSTEMS

Project Tanajib Gas Plant (TGP) PKG # 05 for Security Support

FPI Project No. 12I000623

PO. No. PO-001226
Vendor Doc No. 12-FPISSC-12VDR000263-NAIZ-PHSP001
Rev.01
NMR 602

R00 03 Apr 2023 Issued for Review and Approval JK SP MA

Rev Date Revision Description Prepared Checked Approved

Future Pipe Industries Work Instruction WI: 40
P.O.Box 8513 Revision3
Dammam 31492, KSA
Page 1 of 13

Handling/Storage and
Delivery
(Packing and Shipping GRP/GRE Pipes and Fittings)
Future Pipe Industries Work Instruction WI: 40
P.O.Box 8513 Revision3
Dammam 31492, KSA
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Table of Content

1.0 INTRODUCTION

2.0 PURPOSE
2.1
2.2 PACKING MATERIALS

3.0 GENERAL
3.1 Handling and Storage
3.2 Delivery
3.3 Delivery Note
3.4 Transportation/Handling of GRP /GRE Pipes
3.5 Transportation of GRP/GRE Fittings/Spools
3.6 Return Delivery Note/Packing Slip
3.7 Site Storage

4.0 Insurance

5.0 Health & Safety Procedures

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P.O.Box 8513 Revision3
Dammam 31492, KSA
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1.0 INTRODUCTION
FUTURE PIPE INDUSTRIES LLC is an affiliate company of the "FUTURE PIPE GROUP
OF COMPANIES" who are leading manufacturers of High-Quality GRP/GRE pipes in the
World.
FPI has identified and established quality assurance procedures required for handling,
packaging and delivery of different diameter GRP/GRE pipes and fittings. FPI ensures that
these procedures are being implemented and maintained effectively in order to preserve the
conformity of the finished product and the constituent parts of the product during delivery to
the intended destination.
2.0 PURPOSE
The procedure for handling, packaging and delivery of different diameter pipes has been
identified, established, implemented, and maintained:

• To ensure customer satisfaction by preserving the conformity of the finished product

• For uniformity within the organization
• To ensure all levels of staff are aware of the functions to be carried out by them
• To develop innovative suggestions in a controlled manner

2.1 PACKING MATERIALS

• Packing Materials will be Timber, Bubble Paper and Corrugated Paper.

3.0 GENERAL

FPI has established and maintained a procedure, which details the requirements of
transportation, handling and storage of finished GRP/GRE pipes, fittings, and spools. This
procedure is in line with (01-SAMSS-049).
The delivery department shall be responsible for ensuring that all finished products are
handled and delivered in accordance with FPI’s Handling, Storage & Delivery procedures &
(01-SAMSS-049) requirements and will comply with the packing & shipping specifications
as well as statutory regulations.

3.1 HANDLING AND STORAGE

• The storage surface shall be clean and clear from rocks or any other solid objects.
• Pipes shall be stored separately according to their class and diameters.
• Stacked height shall not exceed more than 2.4 meters.
• Maximum storage deflection shall be maintained as per below:
o Pipes shall be placed on flat timber supports at maximum 6mtr. Spacing with
wooden wedges to prevent rolling in high winds.
o Fittings shall be stored on top of the pallets. Direct contact between products
shall be prevented in the storage area.
o Spools shall be stored in flat area. Ensure that wooden seating beneath spool
is provided as required. Also ensure that contact between products is avoided.
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Dammam 31492, KSA
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3.2 DELIVERY

• The delivery department shall establish whether the finished products are for
immediate despatch or to be placed on hold.
• The delivery department will proceed by packing as per the FPI Standard Packing
Instructions which ae in line with (01-SAMSS-049) and ensure that the packing
materials have been requisitioned and crates prepared, in advance, whenever
practical.
• If the items are for immediate delivery, then the delivery department shall be
requested to transporter to send the vehicle immediately.

3.3 DELIVERY NOTE/PACKING SLIP

Having loaded a vehicle, the delivery note shall be filled with:
• The Customer Name and Address
• Delivery Location
• Project I.D. and Name, if applicable
• Drawing number, revision, Sheet number, Spool number in full including the Pipe
number
• Description of the item and quantity

Delivery Note/Packing Slip shall be produced in I+5 copies. Original - Customer, 1ST Copy
(Blue) - signed and returned, 2ND Copy (Green) - signed, 3RD Copy - signed, 4TH Copy - used
as Gate Pass, unsigned, and 5TH Copy - Office file, unsigned.

3.4 TRANSPORTATION/PACKING OF GRP/GRE PIPES

• Ensure that the GRE pipe ends have been protected with bubble papers/Corrugated
paper before loading on the trailers.
o Threaded ends such as YB pipe will have end caps
o Unthreaded GRE pipes/fittings will be covered shut on both ends
o Flange faces on fabricated piping shall have protective covers not smaller
than the flange outside diameter.
• Ensure that flatbed trailers are used for transporting the GRP/GRE pipes and that the
trailers bed is free from nails/sharp objects.
• Pipes should be uniformly supported throughout the length by flat timber placed
beneath each pipe layers with spacing not greater than 4 meters.
• Chock the pipes with wooden wedges to maintain stability and separation to ensure
no pipe to pipe contact and to avoid abrasion during transit.
• Stake height should not exceed 2.4 meters.
• While in transit, strap the pipes to the vehicle over the support points using pliable
straps or nylon ropes. Never use steel cable or chain without having adequate padding
to protect the pipes from abrasion.
• While loading and offloading the pipes, do not drop, impact, or bump the pipe
particularly at pipe ends.
• While loading and offloading pipes by forklift/crane, fork and steel ropes must be
protected with rubber pads to avoid their direct contact with pipes to prevent
damages.
• When loading/offloading the single pipe by crane, use pliable straps, slings, or ropes
to lift with two support points placed in equal distance to handle the pipe easily.
• In transit, maximum diametrical deflection must not exceed the values in table (a).
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Dammam 31492, KSA
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MAXIMUM DEFLECTION DURING TRANSIT

STIFNESS (SN) MAXIMUM DEFLECTION (%)
1250 3.0
2500 2.5
5000 2.0
10,000 1.5
Table (a)

• Following timber sizes should be used to support the pipes.

SIZE PIPE DIAMETER

100 X 75 mm 1000 mm and above
75 X 75 mm 350 to 900 mm
50 X 75 mm 300 and below
Table (b)

GRP/GRE LARGE DIA PIPE LOADING ON TRUCK (Figure a)

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Dammam 31492, KSA
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GRP/GRE PIPE LOADING & OFFLOADING METHOD (Figure b)

• The pipe shall be chocked by wooden wedges to maintain stability

• No pipe to pipe contact between the layer. So that vibrations during transit will not
cause abrasion.
• While in transit, the pipes shall be strapped to the vehicle over the support points
using pliable straps or nylon ropes.

o Never use steel cable or chain without having adequate padding to protect
the pipes from abrasion.

• While loading and offloading the pipe, shall not be dropped, impacted or bumped
especially at pipe ends.
• While loading and offloading pipes by forklift/crane, rubber pads shall be used to
avoid direct contact of the fork or steel rope with the pipes to prevent damages.
• When loading/offloading single pipes, pliable straps, slings, or ropes shall be used to
lift with two support points placed in equal distance to handle the pipe easily.
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Dammam 31492, KSA
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3.5 TRANSPORTATION/PACKING OF GRP/GRE FITTINGS & SPOOLS

• Ensure that the GRE Fittings(diameter 450 mm and above) end have been protected
with bubble papers/Corrugated paper before loading to the trailers.
• Small diameter fittings of 400 mm and blow shall be packed in wooden boxes. All
the fittings in the box shall be separated by corrugated sheets to prevent damage.
• Small diameter spools of 200 mm and below shall be crated. Spools in the crates shall
be separated by corrugated sheets or corrugated rolls so that direct contact between
products during transportation is avoided.
• Wooden boxes' and crates' bottom construction should be adequately strong to
carry the spools and fittings so that loading, and offloading can be done by forklifts
or cranes.
• Large diameter GRP/GRE fittings and spools shall be transported by trailer. Ensure
that the trailer bed is free from sharp objects like sharp projection or nails.
• Direct contact between products during transportation must be avoided using
corrugated rolls between spools and fittings.
• While in transit, strap the fittings and spools to the vehicle using pliable straps or
nylon ropes.
• When loading and offloading employing mechanical handling, metal slings, hooks
and chains must not come into direct contact with spools and fittings.

GRP/GRE LARGE DIA FITTINGS LOADING METHOD ON TRUCK

(Figure c)
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Dammam 31492, KSA
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GRP/GRE SPOOLS LOADING METHOD ON TRUCK

(Figure d)

• The trailer bed shall be free from sharp objects like sharp projection or nails.
• Trailer bed shall be covered with corrugated sheets or in some cases wooden seating
to be provided with wooden wedges to prevent movement of the fittings and spools
during transit.
• Direct contact between products during transportation shall be avoided using
corrugated rolls between spools and fittings.
• While in transit, fittings shall be strapped to the vehicle using pliable straps or nylon
ropes.
• When loading and offloading, metal slings, hooks and chains shall not come into
direct contact with spools and fittings.
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Dammam 31492, KSA
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3.6 RETURNED DELIVERY NOTES

The delivery note, duly signed/stamped by Customer, will be returned by the Transporter. The
Delivery Department to ensure that the delivery note has been signed/stamped and whether
any alternations, returns or remarks have been made.
After verification, any alterations will be entered into the Computer so that the invoice can be
raised accordingly.

3.7 SITE STORAGE

Storing at site is the client/end user responsibility and FPI’s procedure which is in line with
SAMSS049 to be followed.
• If available, use the original shipping dunnage for storage.
• Pipes are generally stored on flat timbers to facilitate placement and removal of
lifting slings.
• The support timbers should be of sufficient width to prevent point loads.
• Supports that are 4'' (10-cm) wide are recommended for large diameter pipe.
• When stacking, timber supports at the pipe quarter points are best.
• The maximum stack height is typically 8ft (2.4M).
• Rubber ring gaskets should be stored in the shade in the original packaging.
• Fittings shall be stored separately in wooden boxes or equivalent according to their
class, type, and bend degree.
• All fittings in the box shall be separated with corrugated sheet to prevent damage or
abrasion.
• The bottom of the boxes shall support the entire load during lifting and shall allow
handling by a forklift.
• Covering of pipes on site is the sole responsibility of the client/end user unless
otherwise discussed with project leader or concerned party and mentioned in the PO
as no Free of Cost Items from delivery will be provided.
• Lamination kits, shelf life shall be clearly labeled on the product.

4.0 INSURANCE
The Transportation Company shall cover all local deliveries within KSA.

5.0 HEALTH & SAFETY PROCDURE

The loading and offloading areas are perhaps the busiest area on any industrial premises.
Trucks, lifts, trailers, loads, and people are constantly coming and going. Because of the
heavy traffic at the loading and offloading area, the potential for accidents and injuries is
great. That's why safe practices at the loading and offloading area are critically important.
The following Health and Safety procedures shall be complied strictly throughout the delivery
activities to prevent potential accidents, injuries, and even disability.

• Truck and Trailer Safety

• Forklift Trucks - Loading and Unloading Vehicles
• Cranes/Hoists - Loading and Unloading of Vehicles
• Loading & Unloading Checklist
• Safety while using Synthetic web slings.
• Minimum Crane Inspection Guide IO. Personal Protection
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Dammam 31492, KSA
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GENERAL GUIDELINES
Safety at the loading area includes the area, lift truck, and trailer safety. It also includes being
aware of potential hazards (such as spills, unstable loads. etc.) and how to correct them before
an accident can occur. By taking personal responsibility for safety, you can ensure that your
loading area is a safe place to work.
Never store materials in the loading area. The area should be kept free of obstacles and
hazards such as spills. (If spills cannot be cleaned up, they should be clearly marked.) Convex
mirrors throughout the area can reduce blind spots and increase visibility.
LIFT TRUCK SAFETY
Never operate a lift truck unless you are specifically trained to do so.
Always wear seatbelts when operating a lift truck, regardless of how far you're going.
Operators should inspect stacked pallets before lifting to make sure they are secure and
should not lift the load more than 6-10 inches from the floor during transport. Lift trucks
should be inspected and maintained on a regularly scheduled basis.
TRUCK & TRAILER SAFETY
It is required that wedge blocks be placed in front of trailer wheels to prevent vehicles from
accidental movement in the loading areas. Drivers should be advised of emergency brake and
jack measures as well.
FORKLIFT TRUCKS - LOADING AND UNLOADING VEHICLES
What vehicles can you load and unload using forklift trucks?
straight trucks, tractor­ trailers, etc.
How should you prepare the work area for loading/unloading using a forklift truck
operation?

• Set the vehicle's brakes up.

• Check the vehicles' wheels.
• Install fixed jacks to support a semi-trailer that is not coupled to a tractor to prevent it
from pending.
• Post signs warning not to move a vehicle.
• Check that the height of the vehicle's entrance door clears the forklift height by at
least 5 cm (2 in.).
• Make sure floors can support the combined weight of the forklift and the load.
• Inspect interior of a vehicle for the following: trash, loose objects, and obstructions;
holes or weak floors; poor lighting; and low overhead clearance.
• Install anti-slipping material in any area that could be a hazard because of weather
conditions.
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Dammam 31492, KSA
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What should you do to load (unload) vehicles using a forklift truck?

• Keep forks pointed downhill when travelling without a load on a ramp.

• Keep forks pointed uphill when travelling with a load on a ramp.
• Stay clear of edges of roads, or ramps. Have edges clearly marked.
• Do not tow or push trucks with a forklift.
• Do not operate forklifts inside vehicles for long periods without ventilation.
• Do not enter a vehicle if any of these conditions exist.
• Drive carefully and slowly over the plains. Do not spin wheels.
• Cross railway track on a diagonal.
• Do not park a forklift within three meters of railway tracks.
• Do not lift shutter doors with forklift forks.
• No one, except any instructor or designated person should be allowed on a forklift
with the operator whilst in operation.

LOADING AND UNLOADING CHECK-LIST.

1. Check that LOADING AND UNLOADING operations are carried out safely.
2. Are loading/unloading operations carried out in an area away from passing traffic,
pedestrians and others not involved in the loading/unloading operation?
3. Are loading/unloading activities carried out using safe systems of work on ground
that is flat, firm and free from potholes
4. Are the vehicles braked and/or stabilized, as appropriate, to prevent unsafe
movements during loading and unloading operations
5. Is the loading/unloading carried out so that, as far as possible, the load is spread
evenly to avoid the vehicle or trailer becoming unstable?
6. Are checks made to ensure that loads are secured and arranged so that they cannot
move about, e.g. slide forward if the driver must suddenly brake, or slide off if the
vehicle must navigate steep inclines?
7. Are there checks to ensure that vehicles are not loaded beyond their capacity?

CRANES/HOISTS - LOADING AND UNLOADING OF VEHICLES.

Load Considerations
1. Load Radius: the horizontal distance between the centre of the crane rotation to center
of the load.
2. Boom Length: including the jib, swing away extension or any other attachments that
may increase length of the boom
3. Parts of Line
4. Boom Angle: the angle formed between the horizontal plane of rotation and centre
line of the boom.
5. Weight of any attachments: jib, bar extension or auxiliary boom point.
6. Weight of handling devices: ball, block, and/or any necessary rigging.
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Operational Considerations
1. It is very dangerous to lift a load without knowing whether it is within the rated
capacity while expecting the crane to start to tip to warn of an overload. Cranes may
suddenly tip over or the boom may collapse if the load is too heavy.
2. Always stay within the rated capacity. Operators must reduce the load capacity under
adverse field conditions until, it is determined, the machine can safely handle the
load.
3. Loads shall not be allowed to exceed rated load capacity and working radius.
4. Do not use counterweights heavier than the manufacturer's recommended weight.
5. Even a light wind can blow the load out of control, collapse booms, or tip machines.
6. Winds aloft can be much stronger than at ground level.
7. Proper precautions shall be taken when the velocity of wind exceeds 20mph.
8. Crane capacity can be adversely affected when the machine set is not level.
9. Do not lift loads when winds create an unsafe or hazardous condition. Booms should
be lowered, if possible, under high wind conditions.
10. Foot pedal brake locks are furnished on some cranes to allow the operator to rest his
legs when suspending the load for short periods of time. Operators should keep their
feet on the pedals while foot pedal brake locks are in use. Brakes may cool allowing
the load to fall.
11. Only the operator and the instructor are allowed on an operational crane.

SAFETY IN USING SYNTHETIC WEB SLINGS.

Safe operating temperatures
Synthetic web slings of polyester and nylon shall not be used at temperatures more than 180°
F. Polypropylene web slings shall not be used at temperatures in excess of200° F.
Repairs
Synthetic web slings that are repaired shall not be used unless repaired by a sling
manufacturer or an equivalent entity. Each repaired sling shall be proof tested by the
manufacturer or equivalent entity to twice the rated capacity prior to its return to service.
Slings, including webbing and fittings, which have been repaired in a temporary manner shall
not be used.
Removal from service
Synthetic web slings shall be immediately removed from service if any of the following
conditions are present:
1. Acid or caustic bums.
2. Melting or charring of any part of the sling surface.
3. Snags, punctures, tears, or cuts.
4. Broken or worn stitches; or
5. Distortion of fittings.
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Dammam 31492, KSA
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PERSONAL PROTECTION FOR LOADING/UNLOADING PERSONNEL

The loading/unloading personnel are exposed to a high degree of accident/incident risks. They
must always wear appropriate personal protection.
The following PPE is recommended for personnel involved in Loading/ Unloading
operations:

HEAD PROTECTION
All personnel must wear a hard hat for protection from head injuries that may eventually lead
to death.
HAND PROTECTION
All personnel must wear leather hand gloves for protection from sharp edges, rough surfaces,
and injuries during slinging.
EYE PROTECTION
Personnel loading/ handling sharp and projecting items must wear safety goggles for
protection from injury to the Eye.
FOOT PROTECTION
All personnel working in the Stock/Loading yards must wear safety shoes for protection
against sharp objects like nails, wood, stones etc.

Note: For all Aramco Projects, Packing, Marking and Shipment shall be as per 01-SAMSS-
034, 01-SAMSS-029 and 01-SAMSS-049