RTR Piping System

WORK INSTRUCTION

RTR PIPING SYSTEM

TABLE OF CONTENTS

Pages

Issue / Revision Record

3

1.0

Scope & Purpose

4

2.0

References

4

3.0

Definitions & Acronyms

4

4.0

Responsibilities

5

5.0

Procedure

5-8

6.0

Supporting Documents

9

MECH-3-009-310

Issue: 1

Revision: 0

Page 2 of 9

WORK INSTRUCTION

RTR PIPING SYSTEM

ISSUE / REVISION RECORD Issue

Revision

Paragraph

1

0

All

Description Issued for approval

Date 17-Dec-2011

NOTE: Where revisions affect the whole document, No Identification will be placed adjacent to the revised paragraph.

MECH-3-009-310

Issue: 1

Revision: 0

Page 3 of 9

WORK INSTRUCTION 1.0

RTR PIPING SYSTEM

SCOPE & PURPOSE This Procedure shall apply when Installing Reinforced Thermosetting Resin Pipe (RTR Pipes) for the project BI-21-00044. The purpose of this work instruction is to define the RTR Piping System and the responsibilities of various personnel involved, in order to meet Saudi Aramco specification requirements.

2.0

REFERENCE SAES-L-105

-

Piping Material Specification

SAES-S-020

-

Industrial Drainage & Sewers

SAES-B-017

-

Firewater System Design

01-SAMSS-029

-

RTR (Fiber glass) sewer pipe & fittings for gravity flow

01-SAMSS-034

-

RTR (Fiberglass Pressure and Fittings)

SAES-S-010

-

Sanitary Sewers

SAES-S-070

-

Installation of Utility Piping

SATIP-L-350-05

-

Fire Water Distribution Piping Installation

SATIP-S-070-03

-

Thermoplastic and RTR Piping

SATIP-S-070-01

-

Earthwork – Excavation and Backfilling for Underground Utilities

SATIP-L-350-07

-

Cement Line Pipe Installation

Construction Scope of Work 3.0

DEFINITIONS & ACRONYMS SATIP -

Saudi Aramco Typical Inspection Plan

SAIC -

Saudi Aramco Inspection Checklist

SATR -

Saudi Aramco Test Report

SAES -

Saudi Aramco Engineering Standard

SAEP -

Saudi Aramco Engineering Procedure

G.I.

-

General Instruction

ITP

-

Inspection & Test Plan

RTR

-

Reinforced Thermosetting Resin

MSC

-

Metals Services Company

MECH-3-009-310

Issue: 1

Revision: 0

Page 4 of 9

WORK INSTRUCTION 4.0

RTR PIPING SYSTEM

RESPONSIBILITIES 4.1

Project Manager Ensure compliance by all parties to this procedure, Project Quality Plan, Inspection & Test Plan and relevant Customers Specifications, Drawings and current Industry Codes.

4.2

Construction Manager Ensure compliance by all craftsmen to the content of this procedure, Project Quality Plan, Inspection & Test Plan and Customers Specifications.

4.3

Superintendent/Supervisor Ensure compliance by all craftsmen to the requirement of this procedure, relevant Specifications and QC Inspection requirements confirm the availability of all materials, tools, equipment and personnel necessary to complete RTR piping systems in a timely manner.

4.4

Safety Officer check and ensure compliance of all personnel and activities to the safety requirements such as all PPE. Coordinates and arrange tool box meetings to ensure the safe installation of RTR Piping. And also to coordinates with the supervisor to ensure that the work is carried out in the safe manner.

4.5

Material Controller / Storeman Carries out all requirements of this procedure, Manufacturers recommendation, Quality Control Plan and relevant Customer Specifications & Standards. Liaise with QC Inspector.

4.6

QC Inspector Performs inspections in accordance with this Procedure, Quality Plan and Project Standards.

5.0

PROCEDURE 5.1

Material Control 5.1.1

Ensure that storage of materials is in accordance wit Manufacturer's Instructions and Procedure Material Control System.

5.1.2

RTR pipes shall be stored out of direct sunlight in stacks or racks as follows: a) If pipes are stacked on each other, the stack height shall not exceed 1.5m (5 ft). Adequate side support shall be provided to prevent slipping or rolling. b) If pipe is stored on racks or bearing boars, the supports shall be at least 75mm (3 in) wide. Supports shall be spaced on 3m (10 ft) centers maximum with the first supports 1.5m, (5ft.) from the end of the pipe. The stack height shall not exceed 1.5m (5ft.). c) All supporting surfaces shall be free of sharp objects.

MECH-3-009-310

Issue: 1

Revision: 0

Page 5 of 9

WORK INSTRUCTION

5.2

5.3

RTR PIPING SYSTEM

5.1.3

RTR fittings shall be stored in their original containers. Fittings shall be stored under a cover that allows free air circulation.

5.1.4

Gaskets, O-rings, and locking keys shall be stored flat on racks below 38 deg C (100 deg F) and out of direct sunlight.

5.1.5

Adhesive for RTR piping shall be stored in an enclosure where temperatures do not exceed 38 deg C (100 deg F).

5.1.6

Pipes and fittings shall be protected from impact, especially on the ends. Throwing, dropping, bumping and hitting pipes and fittings are prohibited. Pipes shall not be dragged or pushed over sharp projections.

5.1.7

Adhesive containers shall be tightly closed when not in use. Adhesive kits shall be checked to ensure that the indicated shelf life has not expired. Any over age, leaking or opened containers shall not be used.

RTR Pipe Assembly 5.2.1

Joints shall be assembled in accordance with manufacturer’s procedure for a specific application. Heating blankets shall be used to cure adhesive bonded joints. Heating blankets should be applied for at least 45 min.

5.2.2

Components of the mixing kit shall be mixed in their entirely (partial usage of the kit is not allowed) with each other for not less than 60 seconds. During winter it may require to warm them.

5.2.3

Pipe end shall be shaved to the correct tolerance as per manufacturer’s recommendation.

5.2.4

Field-fabricated mitered fittings shall be used.

Installation 5.3.1

Trenching and bedding of utility piping systems shall be in accordance Procedure Standards & Specifications.

5.3.2

Ensure that all excavation works are in conformance with the dimensions and elevations indicated on the contract drawings.

5.3.3

Ensure that the trench bottom is continuous, smooth, free of rocks, and to the line and grade shown on the installation drawings. The trench contour shall not cause the joint angular deflection or the pipe bending radius to exceed the manufacturer’s limit.

5.3.4

Check that the bottom of the trench has a minimum of 150mm (6in.) sand bedding below the pipe.

5.3.5

Sand bedding shall be clean, free of rocks and other sharp objects and compacted to at least 70 percent relative density or 95% proctor density per ASTM D698 whichever is applicable and gives the greater density. Maximum and minimum densities of a representatives bedding sample shall be determined in accordance with ASTM D4253 for all locations. The field density shall be obtained in accordance with ASTM D1556, “Sand-Cone Method”.

5.3.6

Ensure that sand bed is tamped or compacted to provide uniform bearing.

MECH-3-009-310

Issue: 1

Revision: 0

Page 6 of 9

WORK INSTRUCTION

RTR PIPING SYSTEM

5.3.7

Check the trench profile by survey to ensure bends will fit and clear sides.

5.3.8

Ensure that pipe trenches are free of water during lowering and laying operations.

5.3.9

All pipes and fittings shall be carefully inspected for cracks and any other damage prior to laying. Defective pipes and fittings shall not be used and shall be removed from the jobsite.

5.3.10 Before installation the inside of all pipes and fittings shall be examined to ensure that they are free of dirt and other obstructions. Any dirt or foreign matter shall be blown out with air of flushed out with water prior to installation. 5.3.11 Ensure that pipes are adequately protected from damage due to impact shocks and free fall during handling and lowering. 5.3.12 Materials, adhesive, tool availability and compatibility shall be verified in accordance with the requirements of the RTR pipe manufacturer. 5.3.13 Assembly and installation of RTR pipes shall be in strict accordance with the manufacturer’s written instruction. 5.3.14 Unrestrained gasket joint piping must be assembled in the trench. 5.3.15 Ensure that the laying of pipe in finished trenches is commenced at the lowest point, with the spigot ends pointing in the direction of flow. 5.3.16 Pipe shall be laid accurately to the line grade as designated on the job plans. 5.3.17 Night caps and/or end protective caps shall be provided on the end lines of pipe spans that have been laid at the trench at the end day of work. 5.3.18 Backfilling shall be in accordance with Project Standard and Specifications. 5.3.19 Fire Water (FW) RTR Pipe on trench installation shall be in accordance to SAES-S-070, Para. 9.7.3 5.4

Qualification of Installers of RTR Piping 5.4.1

5.5

All installers shall be trained in the proper use of the materials and equipment prior to starting the installation. RTR installers shall be in accordance to SAES-S-070, Para. 8.1 to 8.4.

Hydrostatic Testing 5.5.1

Unless prevailing conditions or regulations require full backfilling of the piping prior to the hydrostatic test, underground piping shall be partially backfilled with all joints exposed during the hydrostatic test. The exposed joints shall be shaded from direct sunlight, and the hydrostatic test shall be performed so that the temperature of the thermoplastic piping material or the temperature of the test does not exceed 40 deg C (104 deg F) during the test period.

MECH-3-009-310

Issue: 1

Revision: 0

Page 7 of 9

WORK INSTRUCTION

RTR PIPING SYSTEM

5.5.2

Gravity sewers shall be tested from manhole or manhole to sump inlet. The upstream manhole may be tested at the same time.

5.5.3

A complete record of tests with accompanying test diagram will be prepared and maintained by Site Quality Control Representative. Diagrams showing method of isolation for system or sub-system to be tested, test fluid and pressure, shall also be prepared for submittal to client for approval.

5.5.4

New piping system shall be flushed clean of loose scale and debris prior to testing.

5.5.5

The test pump shall be on firm ground away from the piping. The pump shall have a relief valve set at 10 percent above the test pressure or a maximum of 170 kpa (25 psig) above the test pressure piping systems.

5.5.6

A calibrated tagged pressure gauge of the proper range shall be used for testing piping systems.

5.5.7

New piping system shall be tested at the pressures given in the Project Standards.

5.5.8

During hydrostatic test, all exposed pipes, joints, fittings valves, and hydrants shall be carefully examined for leakage.

5.5.9

Leaking pipe, joints and fittings shall be replaced.

5.5.10 The hydrostatic shall be repeated after the repair of any defects until the system is proved satisfactory. 5.5.11 The piping shall be satisfactory if there is no evidence of leakage or pressure loss after the specified test period. 5.5.12 Hydrostatic Test of Fire Water Line the pressure at 200 psig and 4 hours duration on exposed joint and shall be in accordance to SAES-B-017 Para.12.6b and 12.6c.

MECH-3-009-310

Issue: 1

Revision: 0

Page 8 of 9

WORK INSTRUCTION 6.0

RTR PIPING SYSTEM

SUPPORTING DOCUMENTS FORM No.

FILE LOCATION

Inspection of Fire Water Distribution Piping Lay-out (Buried & Aboveground )

SAIC-L-2055

DCC (Site)

Installation of Fire Water Isolation Valve

SAIC-L-2056

DCC (Site)

Fire Hydrants, Monitors, Hose Reel and Riser Installation Inspection

SAIC-L-2057

DCC (Site)

Flange Joint Inspection – Gasket Verification and Bolt Tightening

SAIC-L-2014

DCC (Site)

Flange Joint Tightening Inspection Report

SATR-L-2001

DCC (Site)

Assembly and Laying of RTR Piping

SAIC-S-4058

DCC (Site)

Excavation, Placement and Compaction on Non-Subkha Areas

SAIC-S-1005

DCC (Site)

Compaction Testing

SAIC-A-1005

DCC (Site)

Final Inspection

SAIC-S-1007

DCC (Site)

Inspect Joint Preparation of Cement Lined Piping Fabrication or Installation

SAIC-L-2075

DCC (Site)

Inspection of Repair to Cement Lining

SAIC-L-2076

DCC (Site)

RECORDS

MECH-3-009-310

Issue: 1

Revision: 0

REMARKS

Page 9 of 9