YT-PF-Z-16-00202 Rev B Method Statement of GRP - Copy

YANBU II POWER & WATER PROJECT

METHOD STATEMENT FOR U/G PIPING INSTALLATION & LAMINATION OF GRP

Document No. Revision Date of Issue

: YT-PF-Z-16-00202 :B : 06 Mar 2012

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 2 of 47

REVISION INDEX Rev

Date

B

06 Mar 2012

For Review

A

10 Feb 2012

For Review

B A Rev.

For Review For Review Description

Description

06 Mar 2012 10 Feb 2012 Date

Danish khan Danish khan Prepared By

I G Yeo I G Yeo Checked By

S K Hong S K Hong Approved By

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 3 of 47

CONTENTS SECTION

DESCRIPTION

PAGE NO

1.0 OBJECTIVE........................................................................................................... 6 2.0 REFERENCE DOCUMENTS.................................................................................6 3.0 DEFINITIONS AND ABBREVIATIONS..................................................................7 4.0 RESPONSIBILITIES..............................................................................................7 4.1. Site Manager............................................................................................................7 4.2. Discipline Manager...................................................................................................7 4.3. Site QC Manager......................................................................................................8 4.4. GRP Pipe Erection Manager....................................................................................8 4.5. Site HSE Manager .........................9 5.0 PROCEDURES....................................................................................................10 5.1. DELIVERY, HANDLING AND STORAGE..............................................................10 6.2 INSTALLATION................................................................................................16 6.0 MATERIALS......................................................................................................... 26 Site Material Storage....................................................................................................26 7.0 EQUIPMENTS...................................................................................................... 27 8.0 INSPECTION AND TEST..................................................................................... 27 Supplier shall submit the Quality Assurance Plan for Purchaser / Owners‟ approval. 27 Purchaser / Owner retains the right to appoint inspectors who have the authority to follow the progress of the work and the manner in which it is being done, to inspect materials in manufacture or at the point of delivery, to reject defective materials either at the source of supply or point of delivery at any time, or to suspend work which is not being done properly or is not in accordance with the plans and specifications. ..........27 Owner‟s / Purchaser‟s inspector shall have free access to the work and to all parts of the Vendor's plant engaged in work on equipment and materials to be supplied, at all times while work is being performed on this contract. .................................................28 Failure of the Purchaser /Owner to witness any test shall not delay either such test or the proper fulfillment of the specifications and guarantees. The Vendor shall not be relieved from any obligation under the Specifications by virtue of the Purchaser

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 4 of 47

/Owner's attendance at, or failure to attend any such tests, or by virtue of lack of notification of rejection of the results of such tests. .....................................................28 Marking 28 Quality assurance / documentation .............................................................................28 Certification ..................................................................................................................28 Personal Protective Equipment (PPE).........................................................................29 Hazard Identification and Risk Assessment Worksheet...............................................29 Working in a confined space (for excavation 1.2 m and deeper).................................30 Scaffolding Erection over the GRP field joints.............................................................30 Pipe Installation............................................................................................................31 Fit-up and Lamination of joints ....................................................................................31 12 layers should be applied at this stage as “initial winding”.......................................34 NOT BE LESS THAN 30............................................................................................39 movement while the jointing is under progress............................................................39 11.0 RISK ASSESSMENTS ………………………………………………………..40

ATTACHED DOCUMENT 1.

RISK ASSESSMENT TABLE

2.

REFERENCE DRAWING - PLOT PLAN - UNDERGROUND PIPING ARRANGEMENT DRAWING

3.

TYPICAL EXCAVATION PLAN

4.

RIGGING PLAN

5.

TYPICAL SCAFFOLDING PLAN

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B 6.

Method Statement for U/G Piping Installation & Lamination of GRP

SEQUENCE OF ACTIVITY AT SITE 7. TEMPORARY DEWATERING PLAN 8. INSPECTION TEST PLAN

Date of Issue: 06 Mar 2012 Page 5 of 47

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 6 of 47

INTRODUCTION

This Procedure defines the work method for Installation of GRP Piping for YANBU II POWER & WATER PROJECT at Yanbu in the Kingdom of Saudi Arabia.

1.0

OBJECTIVE The purpose of this procedure is to set out the requirements and methods for Installation of GRP Piping. This procedure shall be in compliance with the contract and technical specification implemented on the YANBU II POWER & WATER PROJECT at Yanbu in the Kingdom of Saudi Arabia.

2.0

REFERENCE DOCUMENTS This document is based on the Project Specification, Standard and Contractor’s corporate and Project procedures and fundamentally incorporates the requirements as noted in the following Project Documents. 

Specification & Standard 

Section 02625 - Glass Fiber Reinforced Plastic Pipe (GRP) (For Seawater Pipe) Section 02623

For Service other than Sea Water system





ITP for Piping Work



Section 02200 : Earthwork



Section 02610 : Pipe & Pipe Fittings



Section 02713 : Water Distribution Systems



Section 15103 : Valves & Expansion joints for sea water service



Section 15643 : Condenser & Accessories



Section 15913 : Flow meters (Seawater system)

Contractor’s Project documents 

YT-PF-Z-16-00026

Method statement for Earth work



YT-PF-Z-16-00005

Site HSE Plan



YT-PF-Z-16-00020

Permit to Work Procedure



YT-PF-Z-16-00036

Method statement for excavation of underground structure



YT-PF-Z-16-00208

Method statement for Pressure test of Piping

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

3.0

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 7 of 47

DEFINITIONS AND ABBREVIATIONS -

Client: Power and Water Utility Company for Jubail and Yanbu (MARAFIQ)

-

PMC: Jacobs

-

Contractor: Hanwha Engineering and Construction (HENC) and Hanwha Saudi Contracting (HSC)

-

Sub-Contractor: Contractor’s Design & Engineering, Fabrication and Erection contractor

4.0

RESPONSIBILITIES

4.1.

Site Manager He shall be responsible for implement the company safety plan overall, and follows;

4.2.

-

To ensure efficient execution of works in accordance with project specifications.

-

To arrange necessary equipments from other sites through top management.

-

To arrange necessary manpower required for planned work with along term view.

-

To manage weekly internal coordination meeting for effective monitoring.

-

To encourage the work force for good site keeping.

-

To trace the troubles which hurdle the progress of the project and shooting the same with necessary coordination as fast as possible to avoid time loss.

Discipline Manager He shall be responsible; -

To organize the available resources in the site effectively

-

To report to the Site manager or higher management about the resources requirement

-

To encourage the work force for the safe and productive working culture

-

To deal with the site supervisor for executing earth work in correct procedure at site.

-

To coordinate with equipment controller for routine maintenance as well in case of breakdown issues in order to avoid the time delay in the progress of the project.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

4.3.

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 8 of 47

Site QC Manager He shall be responsible for the overall Quality control of all the construction activities at site, and follows;

4.4.

-

for managing all the necessary inspections, inclusive of witnessing, recording and reporting the results.

-

To ensure that all inspections are executed efficiently and expeditiously in order to comply with the master construction schedule.

-

To ensure the preparation of Inspection & Test Plan as per Project specification requirement

-

To obtain the approval for the same

-

To follow up with Planning section/ construction section for method statement for critical activity

-

To execute and monitor the approved Inspection and Test Plan & Procedures for effective results of the product

-

To initiate the identification of training & recommending the same to the higher management for the team.

-

To initiate the approval of 3rd party Lab approval and coordination for the same as and when required

GRP Pipe Erection Manager 

He shall be responsible for the GRP piping from material handling, Unloading & material storage



He shall prepare work execution plan for erection, hydro test & backfilling



Preparation of all documents related to GRP piping work.



Preparation of Test packages according to P & ID, Piping Instrument Diagram, piping ISO drawings and Sketches



Working with project personnel, resolve technical problems which require engineering expertise



To ensure that all materials and equipments are within the correct specification prior to installation.



Review and correction of hydro test packages for correct system names type of test and other relevant data.



Responsibility to monitor the daily activities on site and evaluate workers.



Performance to insure that the progress of works is in line with the schedule..

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

4.5.

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 9 of 47

Site HSE Manager He shall be responsible for the overall safety of personnel materials and during the construction and pre-commissioning of a Project, and follows;

5.6

equipment

-

To ensure all the operations at the site are conducted to the minimum safety standards, and that they are maintained throughout construction.

-

To coordinate and preside over regular site safety meetings, to attain and maintain effective communications, between Sub Contractor, Contractor and Company’s personnel.

-

To establish policies and procedures for the Sub-contractor Site personnel

-

Monitors the removal of physical, biological and chemical hazards, and training of employees on safety policies, procedures, and regulations. Verifies compliance with health and safety regulations and ensures all necessary records are maintained and prepared according to established guidelines. Manages the participation in Occupational Safety and Health Administration (OSHA) inspections, providing inspectors with appropriate documents and identifying safety measures. Ensures projects are completed on time and within budget. Acts as advisor to health and safety administration team regarding projects, tasks, and operations. Requires a bachelor's degree and at least 10 years of experience in the field or in a related area. Familiar with standard concepts, practices, and procedures within a particular field. Relies on extensive experience and judgment to plan and accomplish goals. Performs a variety of complex tasks. A certain degree of creativity and latitude is required.

-

Site HSE Manager will be fluent conversant in the relative safety regulations of the Company and the statutory requirements of the Kingdom of Saudi Arabia.

Site Supervisor: •

Periodic visits to the job site throughout the duration of pipe installation to advise the contractor on the proper and applicable handling, storage, laying, jointing and site testing procedures necessary to achieve a satisfactory pipe installation..

•

It is the responsibility of the Contractor to make available the pipe installation manual to his installation crew, and to ensure that they are familiar with, and understand the procedures described therein

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 10 of 47

•

It is the responsibility of the Contractor to strictly follow and implement the installation procedures published in this installation manual, as well as any additional advise given by our field representative.

•

The manufacturer shall not be liable for any failures related to installation arising from failure of the Contractor to follow and implement our written installation instructions and any additional advise or recommendation made by our field representative

5.0

PROCEDURES

5.1.

DELIVERY, HANDLING AND STORAGE • Prior to unloading of pipes from trailers, all items shall be inspected for any visual/transportation damages. • Single pipes must be unloaded and handled separately (one at a time). Use pliable straps, slings or ropes to lift single pipes. • Do not use steel cables or chains to lift or transport the pipe. • Care shall be taken to prevent pipes from rolling or falling from flat bed trailer and this shall be attained by using proper supports. • If at any time during handling or installation of the pipe, any damage such as cracks, de-lamination or fracture occurs, the pipe should be repaired before the section is installed. Contact BFRPL for inspection of damage and for recommendation for repair method or the replacement. • The rubber gaskets received along with the pipes and fittings shall be stored in shelter with original packing until it is used at site. • The gaskets must be protected from exposures to grease or oils, which are petroleum derivatives, and from solvents and other deleterious substances.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 11 of 47

Handling of nested pipes: Handling Loading & Un-loading of GRP Materials: Transport and storage 1. Loading Pipes, fittings and prefabricated parts (spools) have to be transported by suitable trucks. These trucks must have flat floors. Check for and remove any projections or nails etc. before each load.Materials must be secured for example by using wedges and wooden supports.These supports must have a minimum width of 10 cm, avoiding sharp edges.Usually the materials are tied in place, using pliable nylon or canvas slings. Chains or steel cables may not be used under any circumstances.

The support distances must not exceed 2.5 m. The width of the supports must be a minimum of 10cm. When pipes are inserted (one inside the other), the support distance shall not exceed 2 m.Flanges must be secured against sliding. Flanges may only be loaded on their sealing face if they are sufficiently protected against damage. The best way for fittings to be transported is in crates or onto pallets. Direct contact between products during transport must be avoided. Pipe ends and machined parts must be protected, for example, by means of straw mats covered by polyethylene sheet or polyethylene netting. Pipes and spools should be lifted by using nylon or canvas hoisting belts with a minimum width of 10 cm and must be lifted at two points, using the largest diameter of the prefabricated part (spool), in such a way that the weight is well-balanced.Any part of the truck has to be protected by

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 12 of 47

wood or rubber wherever in contact with the products.We recommend the use of trucks which can be loaded from the sides. If pipes are handled by a forklift truck, the forks must be covered with rubber or plastic DO NOT LIFT THE PIPE BY PASSING A ROPE THROUGH THE SECTION END TO END.

2- Transporting Pipe If it is necessary to transport pipes at the job site, it is best to use the original shipping dunning when loading the truck. If this material is no longer available, support all pipe sections on flat timbers spaced on a maximum of 10 feet centers with a maximum overhang of 5 feet. Chock the pipes to maintain stability and separation. Insure no pipes contact other pipes, so vibrations during transport will not cause abrasion (Figure 2.1.a).

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 13 of 47

Strap pipe to the vehicle over the support points using pliable straps or rope – never use steel cables or chains without adequate padding to protect the pipe from abrasion. Bulges, flat areas or other abrupt changes of curvature are not permitted. Transport of pipes outside of these limitations may result in damage to the pipes.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 14 of 47

3. Pipe Unloading The unloading of material is the responsibility of the client, unless agreed otherwise. Because of the relative lightness of glass fiber reinforced plastics (approximately a quarter compared to steel) handlers may be tempted to handle it roughly, or unload it by letting it drop of its own accord. This may cause serious damage to the material and therefore FPI material should be handled with care.

Do not use chains, steel cables or clamps during lifting. Nylon or canvas hoisting belts with a minimum width of 10 cm must be used. Standard pipe lengths must be picked up at two supporting points. Ensure that hoisting belts are always put round the widest part. We strongly recommend that the pipes are unloaded one at a time when hoist belt used. Each consignment is carefully loaded and must be inspected on site in order to ensure that no damage has occurred during transportation. This will avoid disputes with regards to responsibilities.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 15 of 47

4. Storage of material In order to avoid damage to the stacked pipes, the following rules are important: a) Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a flat surface. b) Ensure suitable supports are used for example wooden beams, measuring 10 x 5 cm to avoid damage to machined pipe ends, stacking should be undertaken with care. c) The machined ends must be protected for example by polyethylene covered straw mats or polyethylene netting. d) The socket and spigot ends must not touch each other. e) The pipes can be stacked economically by alternating the spigot and the socket, as illustrated below. In order to avoid bending of the pipes, the beams should be laid directly above each other in a vertical line. Supports should be spaced at a max. of 3 meter intervals and about 1 metre from each end. The width of the supports should be at least 10 cm. The maximum allowable stack height is 1.5 meters. However, for diameters of 800 mm and above, a maximum of 2 pipes may be stacked one on top of the other. If the product is stacked too high for long storage periods (6-12 months) and subjected to high temperatures, the supports may cause flattening. It is recommended that the product (in particular machined parts) is stored under tarpaulins or (white) polyethylene sheeting. Pipe stacks should have side supports or blocks to prevent rolling or slipping of the stack during stormy weather. f) If any damage during transportation or installation is noticed such as scratches, cracks or pits, Future Pipe Industries should be contacted for any repair or replacement. Never use any damaged material.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

6.2



Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 16 of 47

INSTALLATION

EXCAVATION A. Excavate

all material of whatever nature encountered to the lines and grades as shown.

1). Excavation includes removal and disposal of pavements and other obstructions on ground surface, underground structures and utilities indicated to be demolished and removed, and all other materials encountered. Please go through the method of statement of excavation of earth work PF-Z-16-00026 for more technical details.

YT-

B. Dewatering : Refer Method of Statement for Dewatering YT-PF-Z-16-00011



HOT WEATHER WORK The gel time decreases as the air temperature increases. In certain situation, this property is beneficial in particular in hot climates. When working in direct sunlight above 40°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



EXTERIOR LAY-UP GRP Vendor’s (FPI) Authorized person will be witnessing the first 2 joints to ensure the work in accordance with standard. A. Grind the outer surface of the pipe B. as per the required minimum bond length mentioned in the provided field recipe.

Extend the sanding of the bond length 20 mm more than the required length to ensure complete bonding of the lamination material is achieved over the minimum specified bond area. B. The maximum time between the grinding operation & lamination process is two hours. In case of delay in starting the lamination operation, the entire sanding operation has to be redone. C. After the component resin/hardener is thoroughly mixed one can start the fit procedure.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 17 of 47

D. The cross section of the pipe has to be protected against penetrating liquid using a resin or adhesive layer. E. After the pipe sections are positioned they should be wetted over a length of approx. 5 cm on both sides of the “weld” using resin/hardener, mixtures, after which the fit layer can be made. F. Wrap 5 layers of 270 gr/m² 5 cm width for dia 25 through 350 mm and for dia 400 through 2000mm 5 layers 270 gr/m² 10 cm width have woven roving around the “weld” taking care that every following layer applied over a totally impregnated previous one. For this impregnation use a brush or roller. The woven rovings are wrapped around under tension. The resin/hardener Mixture will be pressed through the woven roving.

G. Be sure to cure the fit layer over the entire circumference. After curing the fitted part can be moved. In large diameter the fit layer thickness should be increased if the part has to be moved. H. Before continuing, grind again to guarantee a good adhesion between fit layer and laminate. I. After the fit layer has hardened re grind the entire tapered section of the pipe & fill it with pieces of 360 gm woven roving & resin mix until the entire tapered portion is filled in level with the outside diameter of the pipe. Allow the laminate to cure at ambient temperature. This is done to avoid excessive exothermal heat that may interfere during the final welding operation. J. When the above laminate has hardened sufficiently the exterior part of the laminated area as well as the total required bond area should be sanded well for the final welding process. K. Laminate resin and hardener should be mixed in a bucket in suitable quantities by preference mechanically e.g. using a propeller mounted on a drilling machine or manually using a spatula for approx 1 min. The woven roving must be wrapped with an overlap of 50%; this means that 2 layers per winding are generated. The abraded and cleaned surface should be wetted with resin mix, using a brush or lamb’s wool roller. L. Then layers of woven roving should be wrapped around wetted surface. Each applied layer must be thoroughly impregnated. The woven roving requires to be tensioned, so the resin presses out of the underlying layers. For the impregnation of the applied woven roving use a roller or brush.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 18 of 47

M. For diameters up to 150 mm the butt and wrap joint is totally built up from woven roving’s 270 gr/m²; for dia m 25 through 50 mm the width will be 5 cm, for dia m 80 through 150 mm the width will be 10 cm. N. For diameter range 200 mm through 350 mm the butt and wrap joint is totally built up from woven roving 360 gr/m² 10 cm width. The thickness of the lamination must be maintained at 0.75 x the bond area at either end of the joint. For detail of bond area & thickness, please see the required lamination recipe. O. For diameters 400 mm and above the woven roving shall be changed after 12 layers of 360 gr/m² 10/16 cm width into 580 gr/m² 10/16 cm width, which will be applied in 4 layers alternated with 2 layers of 360 gm layers. The first 12 layers (6 double) should always be woven layers of 360 gm. P. For diameter range 700 mm through 2000 mm lamination has to be started using woven roving of 360 gr/m² 16 cm widths. Q. When the required wall thickness is obtained a final layer of 2 layers of woven roving for diam > 350 mm 360 gr/m² 16 cm width should be applied. R. After the 2 final layers of 360 gr/m² 16 cm width woven roving have been applied, the laminate should be finished with 2 layers of reinforced non-woven wrapped over the laminate. S. The superfluous resin should be removed using a rubber scraper plate after which the laminate should be cured at room temperature. Note: For larger diameters it may not be possible to complete the entire lamination process in one go. Therefore the lamination process has to be interrupted in case gelation occurs. The laminate should be allowed to cure at room temperature & later re grinded to continue the rest of the welding process until the required thickness has been achieved. The exact quantity of the material of the butt strap joint shall be issued by FPI Engineering department for each diameter and pressure. 

FURTHER RECOMMENDATIONS

A. Adjacent pipes should not have different self deflections causing joint steps, but where a pipe butts up against a fitting of different thickness, a slight difference in roundness may occur with the pipe being deflected more than the fitting. It is possible to correct this slight out-of roundness on the pipe by using a jacking prop with wooden load spreaders at each end.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 19 of 47

B. Where different thicknesses of adjacent parts are encountered (e.g. pipe to reducer, pipe to elbow, or pipe to tee), the parts should be aligned concentricity and any step greater than 6 mm removed by applying a 15 deg. tapered build up to the pipe surface with glass mat and resin. This should be applied all round the pipe and rolled out as normal. Steps less than 6 mm can be tapered off with resin/cabosil putty or filled with woven roving. The lay up joint can then be applied in the normal manner. C. It is important that when pipe surfaces to be laid up are cleaned with solvent, the solvent must be freshly drawn and clean. The cloths should also be clean, made out of white cotton. The solvent used for this cleaning operating can subsequently be used for cleaning rollers, tools, gloves, etc. Notes of Caution 1). Do not use resin that is gelling (beginning to thicken). 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 layup. 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. 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 (2½% maximum) and / or (2) using the heat of a previous lay-up. Remember never place a lay-up over another lay-up, if the first 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.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 20 of 47

b. Wipe the ground area with clean solvent to remove collected dust and allow the solvent evaporate completely. c. Continue to apply the remaining layers of the lay-up as previously described. 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 of the lay-up is applied. 

INTERNAL SEALING JOINT GRP Vendor’s (FPI) Authorized person will be witnessing the first 2 joints to ensure the work in accordance with standard. Grind the area to be bonded preferably just prior to the welding process. A. Ensure that any gaps between the pipes are filled well with Cabosil/resin mixture or glass roving’s. B. Apply the given nos. of 270 gm woven roving with the resin mixture until the required thickness has been achieved. In cases where gelling occurs discontinue the lamination process & allow to cure at room temperature. Re grind the areas after the curing process is completed & continue the lamination process until required thickness has been achieved. C. Finish the interior layer with one layers of C glass & resin mixture. D. See lamination recipe for detailed bond area & layers. Slightly different procedures and safety measures must be observed when making internal lay-up joints. Make sure proper ventilation is available when working in close environments. Wear safety masks & goggles always when in contact with chemicals.



CURING & FINISHING: The resin/catalyst system is as illustrated in Table 1; the curing curve shown in Figure 1 was obtained in ambient temperature of 20oC and relative humidity of 75%. Adjustments are required to suit local temperature and humidity; good judgment should be exercised.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 21 of 47

Table 1 After well mixing the above and before start the lamination process add 150 g catalyst to each 1 Kg of the above mixture. PRECAUTIONS and EQUIPMENT



The resin, catalyst, booster and accelerator used in performing the lamination are flammable and can cause harm if not used properly. Data sheets of each material should be obtained from supplier and read carefully prior to commencing work. The following list shows equipment that must be supplied by the installation or lamination contractor: -

Rotary disc sander.

-

Carborundum sanding disc 16 grit.

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Polyethylene pots for mixing resin with 1 gallon capacity.

-

1 Pint graduated cylinder for measuring catalyst.

-

Paint rollers 5 cm diameter and 15 to 20 cm long.

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Wooden spatulas for mixing resin & catalyst.

-

Masking tape.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B



Method Statement for U/G Piping Installation & Lamination of GRP

-

Goggles.

-

Rubber gloves.

-

Grooved rollers 7.5 cm long.

-

Dust Masks

Date of Issue: 06 Mar 2012 Page 22 of 47

QUALITY ASSURANCE A. Source Quality Control: The following tests shall be carried out during the manufacturing period: 1). Determination of glass/resin composition as per ASTM D2584. 2). Determination of the Barcol hardness of the laminate as per ASTM D2583. 3). Determination of the laminate strength of tensile bars extended in the longitudinal direction of the pipe as per ASTM D638. 4). Determination of pipe stiffness using a 300 mm long pipe sample, carried out in accordance with ASTM D2412. B. Codes and Standards: The design, material, fabrication, inspection, and testing of all materials furnished shall be, unless otherwise specified, in accordance with the latest revisions of the applicable codes and standards of the following United States regulatory agencies and standards organizations in force on date of Award of Contract. In the event of conflict between this Document and any codes or standards, the Contractor shall refer this matter to the MARAFIQ for resolution. American Society for Testing and Materials (ASTM) American Society of Mechanical Engineers (ASME) American Welding Society (AWS) American Water Works Association (AWWA) International Standard Organization (ISO) National Fire Protection Association (NFPA) Steel Structures Painting Council (SSPC) American Iron and Steel Institute (AISI) Hydronics Institute (HI) Underwriters' Laboratories, Inc. (UL) Pipe Fabricators Institute (PPI) American National Standards Institute (ANSI) C. Material meeting other standards, which ensure quality and safety equal to or

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 23 of 47

higher than United States standards, regulations, and codes, will also be acceptable, subject to the approval of MARAFIQ. In these instances, the Contractor shall be required to demonstrate the equivalency of the standard(s), and shall furnish the MARAFIQ with one copy of the standard(s), used for the design and fabrication of the equipment. D. The Contractor shall be responsible for the quality of pipe in accordance with the material, fabrication, qualification testing, and acceptance requirements of the ASTM Standards and, specifically, the ASME Boiler and Pressure Vessel Code, Section III, Division I, Code Case N-155-2 (1792-2) except as amended herein. Piping supplied shall only be from material manufacturers and material suppliers as defined by the code case. E. GRP Pipe Applicable Documents: In addition to documents listed in 1.5 B, the following documents and references shall be used when applicable as a source for GRP pipe data to fulfill the requirements of this document. 1.) Raw Materials: ASTM D 2393 and D 445 Viscosity of Resin ASTM D 2343 Tensile Properties of Glass Fibers 2.) General GRP Pipe Specifications: ASME B31.1 power piping ASTM D 2996 RTR Filament Wound Pipe ASME Code Case 1792-2 (N-155-2) Nuclear RTRP Standards PS 15-69 GRP Products ASTM D 3139 Elastomeric Joints 3.) Pipe Design Standards: ASME Code Case 1792-2 (N-155-2) Nuclear Pipe Standards

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

ASTM D 2353 Method for Calculating Internal Pressure Stress ASCE Proceeding 37 M & R No. 37 Chapter 9 ANSI B16.1 and B16.5 Standard Dimensions for Cast Iron and Steel Flanges ASTM D 2992 Hydrostatic Design Basis ASTM D 3567 Dimensioning of RTR Pipe and Fittings 4.) Tests for Material Properties of Finished Product: ASTM D 2583 Barcol Hardness of Product ASTM D 638 Tensile Properties ASTM D 790 Flexural Properties ASTM D 695 Compressive Properties of Rigid Plastic ASTM D 1599 Short-Time Rupture Strength of Pipe ASTM D 2105 Longitudinal Tensile Properties of RTRP ASTM D 2412 External Loading Properties by Parallel-Plate Loading ASTM D 2563 Level III Classifying Visual Defects in GRP Laminate Parts AWWA C 207 Steel Pipe Flanges for Waterworks Service (4 in. to 144 in.) F. Factory Tests (GRP Pipe): 1.) General:

Date of Issue: 06 Mar 2012 Page 24 of 47

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 25 of 47

(a) The manufacturer shall test the material for random sections of pipe or fittings at a rate that ensures at least one test lot for every 250 meters of pipe which is produced. The manufacturer shall obtain coupon test samples from nozzle cutouts, miter cuts or from a section of pipe which has not had its thickness increase by the dwell turn at the ends of the pipe section. (b) Factory tests for GRP pipe shall include but not be limited to tests designated in this section. 2.) Destructive Tests: The following random destructive tests shall be performed: (a) Tensile Strength and Tensile Modulus: These properties may be verified by following test methods utilizing strain gages as specified by ASTM D 638. The shape of the sample coupon must be adjusted to accommodate the orientation of the continuous glass filaments. (b) Flexural Modulus: The flexural modulus of the glassfiber component may be determined by measuring a sample coupon with strain gages in accordance with ASTM D 790. The shape of the coupon must be adjusted to accommodate the orientation of the continuous glass filaments. For components of a diameter of less than 2 meters, parallel plate loading tests shall be performed in accordance with ASTM D 2412. (c) Elastomeric Joint Testing: The Contractor shall document joint integrity from tests of previously installed and operating fiberglass piping systems or by means of other testing that the proposed joint is of sufficient strength to survive the anticipated service conditions without leakage or fracture. (d) Testing Resin/Glassfiber Overlay Joints: The integrity and strength of a resin/glassfiber overlay joint shall be analytically evaluated to ascertain that the strength of the overlay joint is at least equal to or greater than the axial strength of the GRP pipe. Visual inspection of the overlay joint will be performed to ascertain its reliability.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B



Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 26 of 47

QUALITY CONTROL The following quality control checks can be done on the completed lamination. - Visual: There is no specific standard for conducting visual testing. Basically the lamination should not have irregularities in shape and appearance. - Dimensional: The thickness and width of each joint is given in the process sheets. Those are the minimum values. PERSONNEL



Lamination works to be done by skilled operators, trained and qualified by Future Pipe. Qualification certificates for laminate application.

6.0

MATERIALS The following material shall be prepared;



-

Fiberglass joint kit which includes:

-

Fiberglass Woven Roving with specific dimensions as per diameter.

-

Vinyl Ester Resin (promoted, not catalyzed)

-

Top tape for the top coat of the joint

-

Catalyst /Hardener

-

Cabosil powder

-

Styrene

-

Inhibitors

Site Material Storage -

Resin – Shall be stored in shelter.

-

Catalyst- shall be stored in a properly regulated store temperature of 20°C to25°C.

-

Fiberglass kits woven roving – shall be stored in a close room to avoid dust, dump and direct sunlight.

-

Styrene – shall be stored in shelter.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

7.0

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 27 of 47

EQUIPMENTS The following equipment shall be prepared;

8.0

-

Rotary disc sander

-

Carborundum sanding disc,60 grit

-

Table : 1 per work crew, big enough to accommodate largest strip of mat or woven roving.

-

10 Liters polyethylene pots for mixing resin.

-

Paint rollers, 5 Cm diameter and 15 Cm. To 20 Cm. Long

-

Solvent e.g. methylene Chloride.

-

Masking tape

-

Safety Goggles

-

Rubber Gloves

-

Heavy, Kraft paper, large enough to cover work table

-

Grooved rollers 7.5 cm long for consolidation.

-

Portable Shed

-

Crawler Crane : 1 set

-

Hydro Crane : 1 set

-

Trailer : 1 set

-

Generator : 3 sets

-

Compressor : 1 set

-

Engine welding machine : 2 sets

-

Fans : 2 sets

-

Pumps

INSPECTION AND TEST -

Materials and finished components shall be subjected to inspections and tests according to applicable Codes and Standards and stipulations of Owner‟s specification.

-

Supplier shall submit the Quality Assurance Plan for Purchaser / Owners‟ approval.

-

Purchaser / Owner retains the right to appoint inspectors who have the authority to

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 28 of 47

follow the progress of the work and the manner in which it is being done, to inspect materials in manufacture or at the point of delivery, to reject defective materials either at the source of supply or point of delivery at any time, or to suspend work which is not being done properly or is not in accordance with the plans and specifications.

-

Owner‟s / Purchaser‟s inspector shall have free access to the work and to all parts of the Vendor's plant engaged in work on equipment and materials to be supplied, at all times while work is being performed on this contract.

-

Failure of the Purchaser /Owner to witness any test shall not delay either such test or the proper fulfillment of the specifications and guarantees. The Vendor shall not be relieved from any obligation under the Specifications by virtue of the Purchaser /Owner's attendance at, or failure to attend any such tests, or by virtue of lack of notification of rejection of the results of such tests.

-

Marking Each pipe/fitting and spool shall be permanently marked with following information: a) Manufacturer‟s name or initials and identification code b) Normal size c) Pressure rating and temperature rating d) Number and date of selected code e) Resin and reinforcement type Upon satisfactory completion of inspection and testing on pipes, fittings and spools, the organizations responsible for design, construction and inspection shall furnish copies of the certificate to the Purchaser, stating the design, construction and testing complies with this specification and selected code.

-

Quality assurance / documentation QA shall be according to requirements in selected codes and manufacturer‟s QAmanual approved by Purchaser / Owner. Detailed design drawings shall be prepared by the Vendor and submitted for Purchaser approval prior to start of manufacturing. All important construction details must be shown in details-drawings.

-

Certification The Manufacturer shall provide quality control test reports. Manufacture shall submit a certified record of inspection and testing together with a statement of

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 29 of 47

compliance with the requirements. These shall also include the relevant certificates for metallic parts, if any. Additionally, requirements of Owner in regards certification stipulated in his specification shall be met. -

The installed pipe lines shall be hydro-tested

-





Personal Protective Equipment (PPE) -

Coveralls

-

Hard hat

-

Safety boots

-

Gloves(rubber and cotton)

-

Safety glass

-

Paper mask

-

Respirator with cartridge (RC202) filters (for internal lamination works)

-

Full body harness(working at height)

-

Face shield to use during the grinding works.

-

Access to suitable fire extinguishers tor internal and external work faces.

-

Eye wash tools on vicinity of the working area (during the lamination work)

Hazard Identification and Risk Assessment Worksheet Equipment mobilization Crane, Boom truck, System including pump, Trailer Truck, Hand tools, Lamination Kits and Accessories Control Measures

 -

Crane must have current 3rd party inspection.

-

Crane operators and drivers must have current SAG license and TUV certificate.

-

Appropriate documents to be sent along with the equipment.

-

Documented pre-deployment maintenance check of the equipment by mechanic.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 30 of 47

-

Crane load chart and operating manual available.

-

Hand signals posted on the crane.

-

Must pass MET- Inspection.

-

Monthly equipment inspection & color coding.

-

Conduct daily inspection using equipment daily inspection checklist.

-

Through inspection of all equipment shall be carried out by a competent person designated by ESD-Equipment Service Department prior to delivery of the equipment to the project.

-

Fire extinguisher shall be provided on every equipment with internal combustion engine, 20lbs.

-

Obtain necessary work permit from MET

-

As built underground drawing and plot plan from MET showing buried facilities and limitation shall be provided.



Working in a confined space (for excavation 1.2 m and deeper) -

Obtain necessary work permit from MET No confined space entry starts without a dedicated trained entry attendant physically available at the entry point. The entry attendant remains outside the space to constantly monitor (by visual or auditory communication) authorized entrants working inside the space.

-

Ensure gas testing is performed in every level prior to entry.

-

Ensure rescue equipments are available.

-

Entry attendant shall maintain al log to fully account personnel inside the space.

-

The space must be evacuated in emergency inside/outside space or hazardous atmosphere is detected.



Scaffolding Erection over the GRP field joints. -

Selecting right scaffold for job.

-

Assigning personal and training.

-

Scaffold inspection and tagging

-

Scaffolding materials proper maintenance and storage.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B -

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 31 of 47

Compliance with PPE requirements use eye/face protection, hand gloves, hard hats and safety shoes.

-

All tools/rigging devices to be used will be checked/inspected and color-coded by competent inspectors.

-

Pipe Installation.

 -

Obtain necessary work permit from MET. -

Sequence of work shall be discussed during daily toolbox meeting before work commence.

-

Lifting plan to be discussed by rigging supervisor along side with crane operator, riggers, assist crew, etc.

-

Only competent person shall perform all rigging works.

-

Lifting gears/tackles shall be inspected prior to use.

-

Use proper length and size of slings and ensure lifting tackles in good condition.

-

Softeners to be used to protect sling from sharp edges.

-

Two tag lines shall be used to control the load.

-

Crane shall be properly set-up and appropriate timber pads to be used.

-

Physical barricade to install and maintain with entry and exit points.

-

“Danger lifting on progress, keep out” signboards to be posted.

-

No erection allowed during harsh weather e.g. wig exceeding 20mph, thick fog, heavy sandstorm, rain.etc.



Fit-up and Lamination of joints

2.0

Lamination joint on GRP piping has two stages: a) Grinding the pipe surfaces (internal, external). b) Application of the layers. c) Witness and approval of Fit-up should be done by the QC Inspector prior to lamination.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 32 of 47

A. External Lamination 1. Fit Layer a. Measure the fit layer bond length from the end of each pipe. b. Grind the above area to remove the topcoat and surface layer of the pipes until the pipes glass fiber are exposed. c. Clean this area by dry clean cloth or paintbrush and ensure that it is fully dry. d. Fill the gap if any between the two pipes with cab-o-seal putty. e. Mix the resin and hardener as per the quantities specified in the recipe to maintain the right ration. f. Impregnate the roughened area with above mixture. g. Apply woven roving glass 270 using a 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass. h. Impregnate the above layers with the resin/hardener mixture. i. Repeat the above two steps till the required number of layers is applied. j. Wait till the lamination is cured under ambient temperature. The curing time of the fit layer ranges between 1 to 2 hours depending on the sunlight.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 33 of 47

2. Main Laminate a. Measure the bond length on each pipe from the middle of the fit layer. b. Grind the above area to remove the topcoat and surface of the pipe until the pipe glass fiber are exposed. c. Clean this area by dry clean cloth or paintbrush and ensure that it is fully dry. d. Mix the resin and hardener as per the quantities specified in the recipe to maintain the right ration. e. Impregnate the above layer with the resin/hardener mixture. f. Apply woven roving glass 270 using 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass. g. Impregnate the above layer with the resin/hardener mixture. h. Repeat the above two steps till the required number of layers is applied. i. Depending on the pipe diameter and pressure class, the type of glass and the number of layers are specified in the lamination recipe. If only glass 270 should be used, skip all the below steps except the last one to end up the lamination with two layers of top tape

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 34 of 47

otherwise move the next step. j. Apply woven roving glass 360 using 50% overlap between each two consecutive windings so that wrapping the full surface will end up with two layers of glass. k. Impregnate the above layer with the resin/hardener mixture. l. Repeat the above two steps till the required number of layers is applied. A maximum of 12 layers should be applied at this stage as “initial winding”. m. If more should be applied, move to the following steps. Otherwise skip all the below steps except the last one to end up the lamination with two layers of Top Tape. n. Apply the specified number of layers of woven roving 580 and 360 alternatively. Each type of glass should be applied in four consecutive layers before changing to the other type. Every two layers should be impregnated before applying the second two layers of the same type. o. Apply two “sealing layers” of woven roving glass 360. p. Impregnate the above layers with the resin/hardener mixture. q. Wind two layers of top tape glass around the laminate to extract the excess quantity of resin and to provide smooth surface. r. The lamination is cured under ambient temperature. Make sure that the joint is undistributed until it cures. The curing time varies between 4 to 8 hours depending on the sunlight exposure and temperature. B. Internal Lamination (Applicable only for  900mm & above in condition that the access to the joint internal area is safe and possible). The following steps are to be done inside the pipes: 1. Measure a length of 50 mm from the end of each pipe. 2. Grind the above area to remove the internal liner of the pipe. 3. Cut several pieces of woven roving glass 270/100 with equal length. 4. Mix the right quantity of resin and hardener. 5. Wet the surface area of internal layer with mixture. 6. Stack several pieces of woven roving on a flat surface and impregnate with the resin mixture. 7. Place the above impregnate woven roving on the joint. 8. Evenly press the surface to flush air traps and blisters using steel roller. 9. Repeat the above three steps until the required thickness is reached. 10. Cover the above laminate with two layers of C glass surface veil material (surface

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 35 of 47

mat) to provide a smooth resin-rich laminate surface. 11. The lamination is cured under ambient temperature.

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

PRECAUTIONS a. The prepared bond surface area should be free from grease, oil, dust, moisture, water, etc. Clean the surface using a clean and dry cloth or a dust brush.

b. Do not move the joint before the laminate is cured. c. Lamination should be stopped in case resin starts gelling. To continue the laminate, surface should be abraded. d. Safety precaution for internal lamination as follows: Internal lamination shall be done immediately after completing the external lamination to

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 36 of 47

limit the entry distance to a standard pipe length. When this is not possible, i.e., where the entry distance is longer than 20 meters the following safety measures shall apply: 1. If required, the client safety personnel to measure concentration of any toxic gas and oxygen inside the pipe before giving clearance to enter the line. 2. Use personal protective equipment before entering the pipe. 3. If required, use a rechargeable lamp or hand torch for enough light inside the pipeline. Usually, the daylight is sufficient at the 1st joint near the open end. 4. Ensure that no blockage at the access of the open pipe end. 5. Use exhaust fan or blower to ensure fume free and to avoid accumulated fumes. 6. Ensure that there is no water present in the line/sections, other wise use dewatering pump and sand bags to prevent flow of water to the joint to be laminated. 7. If required, a watchman should be standing outside the pipe and in frequent verbal contact with the technician working inside the pipeline. 8. If the internal joint to be carried out is more than five standard pipe away, a rope will be tightened from the waist of the technician for easy pull out inside the pipe and to ensure his safety in case something gets wrong inside the pipe. 9. The chemicals are potentially flammable, NO SMOKING inside the pipe is allowed and in all areas where lay ups are being made. 10. If required, technicians will wear fume mask to protect from fumes and chemical smell. 11. A safety guards shall be mounted on the grinders. 12. Follow any safety rules as strictly enforced of the end users and the client.

REPAIR PROCEDURE a. If any lamination joint is found to be leaking cut the joint out and replace it with a pipe piece. Connect this piece by two laminations following the same procedure described above.The same shall be done if the leak occurs on the pipe wall due to impact damage. If possible, the leaking lamination can be removed by grinding it off the pipe completely and re-laminate by a new one following the same procedure described above.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 37 of 47

b. In case of a superficial damage on the pipe, the following steps to be followed. A superficial damage is a scratch within the resin rich outer layer of the pipe. 1. Abrade the damaged area by using emery paper. 2. Use a brush to clean the area from dust. 3. Mix the resin according to the recipe. 4. If it is necessary apply 1 or 2 layers of C-glass. 5. Apply the mixed resin on the damaged surface.

QUALITY CONTROL FOR THE GRP LAMINATION JOINTS. 1. PTS WILL PROVIDE QUALIFIED QA/QC INSPECTORS TO VERIFY THE JOINT SPECIFICATION AS PER THE AMIANTIT PROCESS. 2. VISUAL INSPECTION FOR THE LAMINATED JOINTS FOR EXTERNAL AND INTERNAL WORKS 3. CHECKING THE LAMINATION THICKNESS USING THE PI TAPE ALSO THE LAMINATION WIDTH

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 38 of 47

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 39 of 47

4. BARCOL HARDNESS TO CHECK THE LAMINATION HARDNESS SHOULD NOT BE LESS THAN 30.

.......CAUTION............ 1-Do not use resin if it is near to gel. 2-Never allow solvent to run on un-cured resin (the layers looses bonding strength if solvent got mixed with it.) 3- During rapidly changing in temperature periods, pipes may move due to expansion / contraction, This could effect the bonding strength of the initial lamination plies, if the same are not cured prior to the movement. In such cases, the pipe shall be restrained against movement while the jointing is under progress

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 40 of 47

10.0 SAFETY PRECAUTIONS The chemical components required for the butt-strap joints present certain safety and health hazards if not handled well. Following are the recommendation: HAZARDS;Resin:- Liquid resin contains styrene which is flammable. Its vapors may cause irritation of eyes, nose and throat. Excessive inhalation may cause dizziness, drowsiness or loss of consciousness. Catalyst:- Methyl ethyl ketone per oxide is a strong oxidizing agent and is a fire and explosion hazard. It is irritant to eyes, skin and mucous membranes, and is known as sensitizer. It shall always be stored in original containers & only small quantity shall be taken to the work place as per site activities/ requirement. Styrene:- ( For tools cleaning) The principal hazard is loss of consciousness in case of excessive in halation of vapors .Exposure to high vapor concentration may cause cardiac irregularities. PRECAUTIONARY MEASURES:Work in adequate ventilation. Wear dust / vapor mask while mainly working inside the pipes. All crew members shall use protective / safety glasses and rubber gloves. Long sleeved shirts, long pants and hats of some kinds (depend on client safety requirement) are recommended. “NO SMOKING “sign in all lamination material storage and working area shall be displayed. All materials and chemicals shall be away from heat source, sparks and open flames.

FIRST- AID PROCEDURE:IN CASE OF:Inhalation: Remove the victim to fresh air. Eyes: - Flush exposed eye large amount of flowing water. In case of severity, immediately obtain medical aid from nearest hospital.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 41 of 47

Skin: - Wash skin with soap using enough volume of water.

11.0 Risk Assessments The Sub-contractor safety officer and site management will meet the terms of Health and Safety regulations equally across all FRP installation work activities. All subcontractors employees to carry out a suitable and sufficient assessment of all risks to workers and any others who might be affected by their work activities. This is for the purpose of identifying the measures he needs to take to comply with the requirements and prohibitions imposed upon him by or under relevant statutory provisions. In essence this is a requirement to wherever possible remove the risk entirely, or where this is not practicable reduce and control the risk to the lowest level that is reasonably practicable. Listed below the FRP materials used for jointing works notifying that the MSDS will be submitted to HANWHA HSE Managers :1) Fiberglass woven roving in strips of the width required. 2) Resin (promoted but not catalyzed) of the same type as the tank wall materials. 3) Styrene. 4) Catalyst. The Resin, Styrene and Catalyst used in making the lamination joints are flammable and may be harmful. Materials: Common Name : Resin Hazard: Styrene monomer vapor may cause irritation of the eyes, skin and mucous membranes of the upper respiratory tract. Excessive inhalation may cause loss of consciousness. Repeated skin contact with polyester resin may cause dermatitis. Precautionary Measures: Use with adequate ventilation. Avoid inhalation of vapors and preferably use respirators with filters (chemical usage).

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 42 of 47

Spilled resin should be absorbed with inert materials such as sand; Resin that may have been mixed with peroxide initiators prior to spillage should be mixed with inert filler and removed to an open area. And allow time to gel and cure. Fire Hazards: Liquid polyester resin systems contain styrene which is flammable. “NO SMOKING” in storage or work areas, store in cool place away from flames, sparks , direct sun light steam pipes or other sources of heat. Fight fire with foam, carbon dioxide, or dry chemical type extinguishers. Common Name: Styrene Hazard: Exposure to excessive styrene vapor concentrations may cause irritation of the eyes, skin and mucous membranes. Direct contact with the liquid may cause blistering of the skin. Precautionary Measures: Use with adequate ventilation. NO SMOKING in area where materials is stored or used. Avoid contact with skin and excessive inhalation of vapors. To prevent eye and skin contact use Rubber gloves and safety glass for the technicians at work. Fire Hazards: Styrene is a flammable liquid. “NO SMOKING” in storage or work areas, store in cool place away from flames, sparks , direct sun light steam pipes or other sources of heat. Fight fire with foam, carbon dioxide, or dry chemical type extinguishers. Materials: Common Name: Catalyst The catalyst is an oxidizing agent and is a fire hazard. It is an irritant to eyes, skin and mucous membranes and is known sensitizer. Precautionary Measures:

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 43 of 47

Wear protective clothing, rubber gloves and safety glass to prevent eye and skin contact. Use with adequate ventilation. Avoid breathing vapor. Store in the original containers, in the smallest quantity, isolated from other chemicals and away from heat and open flames . NO SMOKING” in storage or work areas. General Safety Rules to follows during site lamination & materials handling: Sub- Contractor Safety Officer will make sure for all Technicians to fulfill the following safety rules as detailed:Safety glasses should be worn at all time and by all personal in the vicinity of the lamination operation.  The skin of all technicians handling the materials should be protected with rubber gloves, long sleeve shirts, long pants, paper mask and respirator with cartridge (RC202) filter for the internal lamination works.  The chemicals are flammable and shock sensitive. Care should be taken that they are kept away from open flames or sparks and that are stored separately away from work areas and other flammable materials. They should also protect from heat and direct sun light.  A “NO SMOKING RULE” should vigorously be enforced in all areas where lamination is being made.  All sub-contractor technicians will wear a respirator with filter during the lamination works.

WORK IN CONFINED SPACES • • • •

Only authorized to suitable trained personnel shall be allowed to enter into confined spaces (such as FRP pipe line). No work whatsoever shall be undertaken without first referring to the current Risk Assessment for the work to be undertaken. A 'Permit to Enter a Confined Space' is to be issued by the relevant trained personal or Supervisor or his authorized assistant prior to each and every entry. Personal Protective Equipment - Gloves, overalls, safety boots, safety helmets, eye protection etc, and is to be worn as appropriate to the task.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B • •

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Date of Issue: 06 Mar 2012 Page 44 of 47

Sub-contractor will provide exhaust fan with a size enough to have good air circular ventilation inside the FRP pipe line. HANWHA will provide the gas tester equipment and trained personal to use and monitor the oxygen percentage in the atmosphere. Records and such training shall be maintained by sub-contractor safety officer in cooperation with HANWHA HSE Managers and will be entered to the permit to work. Sub-contractor will identify qualified personal for confined space stand by men and to be trained from HANWHA HSE Managers. His responsibilities to monitor authorized entry to confined space in accordance with the permit to work conditions, to maintain contact with those inside the confined space ant raise the alarm and provide initial controlling the event of any emergency. Records of any such training shall be mentioned by sub-contractor HSE office. Each Lamination group of technicians (4 Techs.) should have separate suitable fire extinguisher to use at the time required and be trained to use them. First aider and paramedic’s response. Ambulance response and treatment by HENC doctor and or hospital Proper communication equipments and contact numbers (Emergency contact numbers attached) •

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Method Statement for U/G Piping Installation & Lamination of GRP

nsure PTW is processed by authorized and

Competent persons.2.1.2 Ensure effective supervision and conduct inspection. Conduct tool box talk prior to starting work to the force by using the TBT (Tool Box Talks) prompt card. Confirm they all understood the task, hazards and safety precautions and actions to be taken in case of emergency.

WORK AT NIGHT All activities shall be followed as bellow: • Equipment shall be checked in good working condition before using. • Trained workers only shall be allowed to perform each task. Adequate supervision shall be provided o enforce procedure and to guard against untrained authorized worker. • Visible access for personnel shall be prepared on the slope surface. All equipment and material shall be located at least 2 meter away from the excavation.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B •

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Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 45 of 47

Watchman shall be used and control all equipment to warn personnel or other equipments, motor vehicles to keep safe distance from working equipments. All vehicles shall have safe distance during excavation works to avoid accident. Watchman shall also used to warn and prevent colliding with each other. Back alarm is installed on all equipments to serve as warning signal prior to backing out the equipments. All personnel working in night must wear reflective vests. Flash light shall be provided to the foreman and supervisor/ watchman.

LOADING / UNLOADING •

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Provide warning tape or wood cap in all extruding sharp edges. Unwanted materials should not be pile at the work area. The workers who perform the job must be trained. Barricade and signage should be provided in working area. Always avoid blocking the access with materials. Perform good house-keeping in the work area Don’t lift the load beyond the capacity of the equipment. All material must be arranged in proper place after finishing your job. Access must be clear. Transport materials / loading / unloading movements of vehicle The vehicle should be inspected by HENC prior to using. Ensure periodic maintenance of vehicle. Do not over speed and avoid sudden breaking. Ensure proper plan to transport and loaded material. Plant and vehicle to be operated by experienced and licensed operators / drivers. Transport to agreed location. All workers will be ensured to use PPE. Proper assistance given by the supervisor. Adherence to lifting and rigging plan. Licensed driver will be ensured to drive. Passage of movement will be confirmed to driver. Crane operator to inspect the area for suitability for staging the crane and space for extending out rigger.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B •

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Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 46 of 47

All the lifting equipment and tackles shall be inspected prior to use. All lifts to be carried out by competent rigging crew approved by TUV and crane operator, using proper lifting tackles. Unloading of the materials should be conducted without standing on the material. The entire job should be properly planned and scheduled in advance to inimize confusion and shortcuts. Equipment to be in good order and inspected before use by contractor. Ensure experienced and licensed operators by contractor. Ensure experienced, competent rigger to control the lifting equipment. Competent rigger / banks man to attach lifting equipment. Establish exclusive zone and ensure use of PPE. Locating of lifting points will be ensured to operator. Passage of travel will be ensured to operator. The area under shifting will be cleared without workers and crane to be relocated at a safe area. Competent rigger will inspect lifting equipments. Timber, soft or suitable material shall be used between sling belt and steel members.

SCAFFOLDING • • • • •

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Engage skilled workers for the work. Inspect all the tools and discard the damaged ones. Ensure that all workers know use of tool. Ensure effective supervision and conduct inspection. Conduct tool box talk prior to starting work to the force by using the TBT (Tool Box Talks) prompt card. Confirm they all understood the task, hazards and safety precautions and actions to be taken in case of emergency. Ensure PTW is processed by authorized and competent persons. Anchor always to a lanyard. Provided proper guard rails. Never ride of scaffold being removed. Make sure that toe boards and handrails are secure. Barricade the areas to which objects can fall.

YANBU II POWER & WATER PROJECT Contract PO No.: 7200 018 725 Doc No. : YT-PF-Z-16-00202 Rev No. : B

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Method Statement for U/G Piping Installation & Lamination of GRP

Date of Issue: 06 Mar 2012 Page 47 of 47

Don’t permit the workers to enter the barricade area. All Persons should wear the hard hat and adequate PPE Provide ladder extension of one meter above landing platform. Use another person to hold the ladder. Do not use last 2 top rungs. Materials should not be pile stocked over the platform. Good housekeeping should be maintained. Keep Electrical Cord Wire out of the walk away. Working platform shall be fully planked and tied properly with to board and guard rails. Provide proper size of platform to suit the working area. Only trained and authorized persons shall work at height. Follow scaff-tag system to identify the status of scaffolding by the trained and competent person

EXCAVATION • • • • •

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Safe Work Permits and other pertinent documents shall be secured before any works commence. Sequence of work shall be discussed during daily toolbox meeting before work commence. Equipment and tool inspection must be carried out. Safety Officer assigned in the area to check safe work plan/excavation permit prior to actual excavation. Permit should be placed at the work site. Excavate in accordance with the approved Work procedure. Observe proper sloping/benching Competent Supervisor to oversee actual excavation. Back-up/reversing alarm of loader, truck, crane, excavation etc. must always in good condition/operational. Soft ground / newly backfilled areas must be marked / identified. Provide adequate and appropriate access for personnel. Use of full body harness and life line / anchorage point. Providing physical barricade (scaffold tubes or equivalent). Install safety warning signs – “Danger Deep Excavation”.