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Table of Contents

SECTION SUBJECT
1 SCOPE

2 PURPOSE

3 DEFINITION

4 QUALITY CONTROL

5 REFERENCE

6 SAFETY

7 RESPONSIBILITY

8 EQUIPMENT & TOOLS

9 MATERIALS STORAGE & HANDLING

10 QUALIFICATION OF INSTALLERS

11 ASSEMBLING & LAYING OF RTR PIPE

AND FITTINGS

12 HYROSTATIC & GRAVITY TEST

PROCEDURE

13 REPAIRING

14 BOLTS TORQUING
  
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1 SCOPE
This method statement covers the installation, jointing and hydro testing (pressure &
gravity test) of underground reinforced thermosetting resin (RTR) piping system, these
activities include, but not limited to storm water, oily water sewer, fire water, utility water
and drinking water. This statement describes the steps to be followed in performing GRE
Taper & Taper Adhesive Bonded joints of diameter 25 to 1000 mm. This procedure is
applicable for pipe to fitting and pipe to pipe joints.

2 PURPOSE

The purpose of this method statement is to provide for the requirement which shall be
followed when, transporting, handling, laying, joining, and hydro testing for RTR piping
system.

3 DEFINITION

For the purpose of understanding this method statement, the following definitions will be
applied.
RTR Reinforce Thermosetting Resin pipe
U/G Underground
RFI Requests For Inspections
ITP Inspection and Test Plan
  
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4 QUALITY CONTROL
Compliance with the standards specified in this section and the following code reference,
manufacturers recommendations and latest edition of associated publications, which
govern RTR U/G piping installation and hydro testing.
5 REFERENCE
All referenced specifications, standards, codes, forms and drawings shall be of the latest
issue unless stated otherwise.

5.1 Saudi Aramco Engineering Standards

 SAES – S – 070 Installation of Utility Piping Systems

 SAES – S – 040 Saudi Aramco water systems

 SAES – S – 020 Industrial drainage & sewers

 SAES – S - 010 Sanitary sewer

 SAES – L – 610 Non metallic piping

 SAES – A – 004 General requirements for pressure testing.

5.2 Saudi Aramco Materials System Specifications

 01-SAMSS – 024 Piping Handing and Nesting.

 01-SAMSS – 029 RTR(Fiberglass) Sewer Pipe & Fitting for Gravity Flow

 01-SAMSS – 034 RTR(Fiberglass) Pressure Pipe and Fittings.

5.3 Vendor(Bondstrand, Ltd) Instructions

 SBP3-HA61-AMT-0201 General Dimension Drawings
  
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 SBP3-HA61-AMT-0211 Pipe Support Detail Drawings

 SBP3-HA61-AMT-0504 Inspection and Test Procedure for Hydrotest

 SBP3-HA61-AMT-0601 Consumable Materials & Recommended

Special Tools

 SBP3-HA61-AMT-0801 Instruction for Site Installation

 Assembly instructions for BONDSTRAND Taper/ Taper adhesive-

bonded joints

6 SAFETY
Protection & safety shall be in compliance with Construction Safety Manual approval by
Aramco.
Work permit will be available at the work site all the time.
The Storage and handling of adhesive shall be as per vender’s instruction &
manufacturer recommendation.
The working trench for piping shall be cordoned by warning tape to restrict
unauthorized entries and workers will stands well clear while pipes are lowers into the
excavations All lifting equipment must be inspected for defects prior to use. SWL
(Safety Weight Limit) must be visible on all slings. For the safe operation of the shaving
tools, the equipments will be inspected prior to use. Only trained and qualified operators
will operate the shaving machine and authorized persons are to be allowed in the
shaving area. The following personal protection gear must be used when cutting,
shaving sanding and grinding RTR piping materials. Safety shoes or boots and a hard
hat. Working gloves and eye protection (RTR piping material can be very sharp and
may cause cuts or splinters) An appropriate dust mask is to be used when cutting,
shaving, grinding and sanding The proper work permit will be applied for hydrostatic
  
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test. The testing area will be barricaded and signage posted during hydrostatic test
Workers shall be informed of all safety requirement related to the activity through a
tool box meeting.

The following safety precautions shall be taken when with GRE products. While
cutting and grinding the following personal protection shall be used to avoid skin irritation
and inhaling dust.
 Dust mask
 Safety glass
 Hand gloves
 Coverall
 Safety shoes
 Safety helmet
When working with adhesive kits try to avoid direct contact with the skin. If the mixture is
contact with the skin wash with clean water and soap before it becomes hard.

7 RESPONSIBILITIES

It will be the responsibility of the project / site engineer to ensure that all involved
personnel are familiar with the requirement and implementation of this procedure as
applicable to the construction activities.
The inspection and test plan shall be performed as defined here in and witnessed by
RTR U/G piping inspector as applicable. All testing and inspection activities shall be
coordinated with Samsung and Saudi Aramco as per the relevant ITP.

8 EQUIPEMENT & TOOLS

  
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 Ameron pipe shaving tools

 Electrical power drive

 Hacksaw and disc grinder

 Small electrical or air hand drilling machine

 Crane

 Boom truck

 Trailer

 Generators

 Flapper wheel sander

 Pairs of winches or come-alongs

 Pairs of band clamps with puller rings

 Measuring tape and/or folding rule

 PI-Tape with venire division

 Ameron heating blanket

 Pipe vice or stable supports(brackets) with pipe holding or clamping

 Gloves, dust mask and goggles

 Tenting (subject to weather conditions)

9 MATERIALS STORAGE & HANDLING

  
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Storage and handling of RTR pipes shall be in accordance with SAES–S–070 section 5
and 01-SAMSS-024, 01-SAMSS-029 and 01-SAMSS-034. Incoming material,
prefabricated spools and fittings shall be inspected and examined for cuts, scratches,
cracks, damage, buckles and ultra violet damage before acceptance for site storage.
Damaged pipe length shall be cut out and discarded All RTR fitting shall be visually
inspected for damaged ends, delaminating, crushing, weathering, cracked ’O’ ring and
gasket as per 01-SAMSS-029 table 2 and 01-SAMSS-034. Care shall be taken in
handling RTR material in particular that ends shall be protected against any impact. RTR
material shall not be thrown, dropped, bumped, hit and pushed over abrasive surface.
Site Storage of the Adhesive kits

The site storage of the Adhesive kits should be mentioned under an ambient
temperature Of 350 Celsius & under a shaded area.
10 QUALIFICATION OF INSTALLERS

Personnel shall have been trained in the proper use of the materials, tools and
equipments prior to starting the installation of RTR underground pipes. Training shall be
done at the manufacturer plan i.e. Bondstrand (DAMMAM) in K.S.A The installers for
RTR piping system shall be obtained training certificate (or a proof of training) from
RTR piping manufacturer(Bondstrand Ltd.). A training log will be maintained to
indicate the names of trained installers.

11 ASSEMBLING & LAYING OF RTR PIPE AND FITTINGS

11.1 PIPE CUTTING

  
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11.11 Measure the desired pipe length to be cut and scribe the pipe using a pipe fitter’s wrap-
a-round and a marker pen. Ensure the pipe is adequately supported or clamped on a pipe vise
provided with rubber sheet.
11.12 Cut the pipe using an electrical angle grinder attached with an abrasive cutting disc
(diamond grit or carbide grit). Ensure the cut ends are square.
11.13 The cutting point shall be away from the conical part of the socket at a distance of
three times longer than the bell end. The pipe section shall be adequately supported near to
the cutting area.

11.2. MEASURMENT

11.21 Mark the required spigot length.

11.22 Assemble the desired mandrel to the shaft and insert the same into pipe. Keep the
mandrel in position and rotate the handle clockwise until the mandrel tightened against the
inside of the pipe. Ensure the whole length of mandrel is inserted inside the pipe.
11.31 Position the shaver mainframe, power drive and collect nut over the shaft. Rotate the
collect nut anti-clockwise to discharge the feed and pull back the main frame against the
collect nut.
11.41 Adjust the cutting tool as per the required dimension.
11.51 Start the power drive for calibration. The tool post should rotate in a clockwise
direction.
11.61 As soon as the spigot end has been machined to the required length, stop the power
drive. Loosen the collect nut clockwise to disengage and pull out the collect nut, power drive
and main shaver frame.
11.71 Use PI tape to measure the OD of the machined end, if more machining is required,
repeat step2.3 to 2.6.
11.81 Rotate the shaft anticlockwise to loosen the mandrel, after which it can be removed.
  
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11.91 Ensure the machined ends are according with the required measurements within the
specified to tolerance. Clean the calibrated spigot with a clean dry cloth or use a dust brush.

11.3 FACTORY SHAVED SPIGOT

The factory-shaved spigots are in accordance with the required measurements within
the specified tolerance. The spigot shall be abraded using emery cup of grade 40 or 60
inserted in a rubber mandrel and fixed to a drilling machine.

11.4 PRECAUTIONS

The prepared bond surface area must not have any grease, oil, dust, moisture, water,
etc. If any grease or oil is noticed on the bonding surface, soak a piece of cloth with acetone
MEK (methyl ethyl ketone) or MIBK and clean the surface. If the bond surface is cleaned
with solvents re-sanding shall be carried out to refresh the surface. Do not use paint thinner,
petrol etc., for cleaning purpose.

11.5 ADHESIVE APPLICATION

11.51 Prior to the application of adhesive on the spigot and bell fix the latch belts on both
sides of the pipe. Leave enough working space between the pipes to be joined. Use wooden
blocks to prevent damage from come-along-jack. Ensure the pipe sections are adequately
supported and aligned from properly. Check if the prepared bonding surface is clean and free
from dust, oil etc., sand it with an emery cloth and make it fresh prior to applying the
adhesive mixture. Mark the required length to be inserted in to the bell. The prepared
bonding surface should not be touched with a bare hand or with dirty hand gloves.
  
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11.52 Add the hardener from the small container to the resin in the large container and mix
with the supplied spatula for about 3 minutes until the mixture has a uniform color. Adhesive
components should not be mixed partially from the container to avoid proportional mixing
variations. The expiry date of adhesive components shall be checked before using the product
at all times.

11.53 Once the adhesive is mixed properly, apply a thin, uniform layer of adhesive mixture to
the freshly prepared bond surface of the bell end (apprx 0.5mm thick). Do not apply excess
quantity of adhesive mixture to the bell end to avoid excessive formation inside the joint.
11.54 Apply the adhesive to the freshly prepared spigot. The initial layer should be thin and
uniform to ensure the surface area is properly wet with the mixture. Once the entire spigot
area is wet with the mixture apply enough quantity of adhesive to the spigot (approx 1.0 mm
thick). It is important to ensure that no dust/sand or any other particles are mixed with the
adhesive or on the mixture spread of the bonding surface.

11.55 Precautions

11.56.1 In humid environment the prepare joint may need to be warmed up to avoid moisture
contents on the bonding surfaces. Use a heating blanket to warm up the joint. Once the
warming process is completed the joint shall be re-sanded before applying the adhesive
mixture.

11.56.2 The bonding process shall be performed within one hour after preparing the bond
surface, if not re-sanding shall be carried out.

11.56.3 Never use the adhesive, which has started curing or turned tacky.
  
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11.56.4 The adhesive mixture will cure too fast if it is mixed above 40 0C and the work shall
be carried out within the pot life after mixing the two components.

11.56.5 A qualified technician shall perform the joining of all adhesive bonded joints.

11.6 ASSEMBLY

Pull the pipe sections together with the end of the come-along-jack, ensuring the
required length of the spigot is entered into bell end. Ensure that the vertical and horizontal
alignment of the two sections is maintained during insertion of spigot end into the bell. Clean
the excess quantity of adhesive formed around the joint. The bonded joint should not be
disturbed under any circumstances during the curing period.

11.7 CURING

Ensure the bonded joints are self cured by ascertaining the applied adhesive is tack
free. Wrap the appropriate heating blanket around the joint ensuring the bond area is fully
covered (tie up the heating blanket with a securing wire). Close all the open end of the pipe
section to avoid any air breezing into the section. Connect the power cord in to a power
socket. Switch on the temperature controller supplied with heating blanket to the required
temperature of 900C. Ensure the heating device is functioning throughout the process of
heating. The required curing time for RTR Taper and Taper Adhesive joints are 1 hours and
it depends on the wall thickness. The curing time starts when the adhesive reaches 90 0C.
Once the heating process is completed allow the joint to cool down and remove all the
fasteners and materials from the joint. Once all the process is completed the joint is ready for
use.
12 HYDROSTATIC & GRAVITY TEST PROCEDURE
  
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For RTR piping, the hydrostatic test has to be carried out after hunching and

Backfilling have been placed. All joints shall remain uncovered during hydro testing.

The hydrostatic test shall be carried out as per SAES-S-070 section 18 hydrostatic test.

The hydrostatic Test Packages shall be prepared and submitted to Aramco for review
and/or approval prior to conducting the hydrostatic tests of piping. The QC Inspector has
to ensure that all punch lists are cleared before filling of water. System undergoing
testing shall be cleared from any debris along the trench and bottom of pipes at the joint
have at least 6 inches minimum distance from the ground. Gravity sewers shall be tested
from manhole to manhole, or manhole to sump inlet. The upstream manhole may be
tested at the same time. During hydro test, all exposed pipes, pipes joints and fittings
shall be carefully examined for leakage. Leaking pipes, pipe joints and fittings shall be
replaced or repaired in accordance with SAES-S-070, section 20 Repair Methods. After
replacing the defective pipe system, the hydrostatic test shall be retested until the system
is provided satisfactory. The piping shall be accepted if no leakage is observed in
duration of test.

13 Repair Procedure

Permanent repairs for RTR piping, if required, shall be carried out as per SAES-S-070
section 20 Repair Methods.
Field repair of RTR pipes shall be carried out in accordance with manufacturer’s
(Bandstrand) recommended repair procedures.

Procedure Details:
The easy and most convenient method to fix the RTR pipe or Fittings leakage during
hydro static test is Bondstrand Butt and Wrap Lamination there are two instances in
lamination they are following
  
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Instance 1
When there is a pin hole or the leak occurs on the pipe or fittings wall due to impact
damage the repairing procedure is the following steps to be followed. A pin hole or
superficial damage can be scratch within the resin rich outer layer of the pipe. Abrade the
damage area by using emery paper or grinding disc. Use a brush to clean the area from dust.
Mix the epoxy resin according to the recipe. If it is necessary apply 1 or 2 layers of C-glass.
Apply the mixed resin on the damaged surface. And following the procedure of performing
lamination joints.

Instance 2
If any RTR Taper and Taper Adhesive 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
procedure of performing Bondstrand lamination joints procedure.
The Bondstrand Butt-and-Wrap Lamination Procedure is attached with this procedure
  
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14. Torquing Procedure:

Torque should be applied in multipasses following a cross pattern to reduce wrapping

of flange, crushing the gasket, and to minimize cross talk in achieving bolt preload.
Pass Torque
1 1⁄₃ of final torque (T). Start at bolt no. 1 and follow cross pattern
2 2⁄₃ of final torque (T) following cross pattern
3 At final torque (T) following cross pattern
4 At final torque (T), start at highest bolt number and tighten in a
Counterclockwise sequence the cross pattern is easily followed once the bolts are numbered
in the flange. Randomly select a bolt and designate it as bolt number 1. Proceed in a
clockwise motion to the next bolt and add four to the previous bolt number. Moving
clockwise, the next bolt number would be 1, 5, 9, and so on. This system of adding four to
the previous bolt number continues until adding point, start again at bolt number 3. Continue
in the same clockwise direction, numbering bolts 3, 5, 11, and so on until again this number
is larger than the total number of bolts in a flange. At this point the next number is 2;
continue as previously described: 2, 6, 10, and so on. The last series of bolt numbers start
with bolt number 4 and continue 8, 12, 16, and so on. A sample 16-bolt flange showing a
typical cross pattern is shown in Fig. A7.19.
  
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Here find the attached Bondstrand assembly instructions for Flanges