SATORP JUBAIL EXPORT REFINERY

PROJECT

METHOD STATEMENT
ASSEMBLY AND INSTALLATION OF RTR PIPES

Doc. No: JERP-TR-NSH-P-MS-001 Rev.: 01, Date : 23/10/2010

CONTENTS

TABLE OF CONTENTS

1. SCOPE

2. PURPOSE

3. REFERENCES

4. DEFINITIONS

5. PROCEDURE

5.1 RESPONSIBILITIES

5.2 TOOLS AND EQUIPMENTS

5.3 MATERIAL STORAGE AND HANDLING

5.4 QUALIFICATION OF INSTALLER

5.5 PIPING AND FITTINGS MATERIALS TRACEABILITY

5.6 FABRICATION

5.7 INSTALLATION AND REQUIREMENTS

5.8 THRUST AND ANCHOR BLOCKS INSTALLATION

5.9 BEDDING AND BACKFILL

5.10 VALVE INSTALLATION & BOLT TIGHTENING PROCEDURE

5.11 HYDROTEST AND FLUSHING PROCEDURE

5.12 SAFETY

5.13 RISK ASSESMENT

5.14 TRAINING AND INFORMATION

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METHOD STATEMENT
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Doc. No: JERP-TR-NSH-P-MS-001 Rev.: 01, Date : 23/10/2010

1. SCOPE

To establish guideline for the fabrication & installation of Reinforced

Thermosetting Epoxy-Resin pipes, fittings & Fiber glass Reinforced plastic for
Saudi Aramco Jubail Export Refinery Project.

2. PURPOSE

This method statement is made to enumerate the procedure in the fabrication &
installation of Reinforced Thermosetting Epoxy-Resin pipes & fittings for Saudi
Aramco Jubail Export Refinery Project.

3. REFERENCES
3.1 SATORP STANDARDS
 JERES-L-105 Piping Material Specification
 JERES-S-070- Installation of Utility Piping Systems.
 JERES-A-004- General Requirements for Pressure testing.
 JERES-L-610- Non Metallic Piping
 JERES-S-060- Plumbing Code
 JERES-A-114- Specification for Excavation and Backfilling
 JERES-S-020-Industrial Drainage And Sewers
 JERMS-L-1029- RTR sewer Pipe and Fittings for gravity flow.
 JERMS-L-1034- Unrestrained Gasket Joint RTR sewer Pipe and
Fittings.

3.2 CONTRACTOR Project Procedures

 SA-JER-DSAAA-TRJR-509101 Excavation / Compaction / Backfilling
Works.
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3.3 Industry codes and standards

 ASTM D4024 – Reinforced Thermosetting Resin Flanges
 ASTM D3839 – Standard practice for underground installation of RTR.

4. DEFINITIONS

COMPANY SATORP (JV between Saudi ARAMCO and TOTAL)

CONTRACTOR Técnicas Reunidas. TRJR (Técnicas Reunidas Jubail Refinery),
OOK entity and TRG (Tecnicas Reunidas Gulf), IK entity.
NSH Nasser S. Al-Hajri Corporation ,Kingdom of Saudi Arabia
SUPPLIER (or Any person, firm, partnership, company, corporation or
VENDOR) combination thereof with which the BUYER has sent the
QUOTATION REQUEST or placed the PURCHASE ORDER.
SUPPLY All material, equipment and services to be provided whether
expressly or by implication under the PURCHASE ORDER.

5. PROCEDURES

5.1 RESPONSIBILITIES

5.1.1 Project Manager shall be responsible for the overall implementation of

the company safety & Quality plan and ensure efficient execution of
works in accordance with project specifications.
5.1.2 QA/QC Manager shall oversee all the activities, whether all are
executed as per the quality plan and project specifications.
5.1.3 Construction Manager shall be responsible to give correct instructions
to supervisor for Implementing the project quality and safety plan.
5.1.4 Supervisor shall monitor the execution of all works and submit RFI in
time 24 hours prior to inspection. Foreman shall lead the work force
and workmanship during the execution of the work.
5.1.5 QA/QC Engineer shall ensure that all records pertaining to the
particular works are maintained and accepted by TRGC/SATORP.
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5.1.6 QC Inspector shall ensure that all works are carried out as per IFC
Drawings, project specifications and standards and he has to co-
ordinate with TRGC/SATORP QC Inspectors for inspection.

5.2 TOOLS AND EQUIPMENTS

 Powerpull (2X)
 Joint Lubricant
 Band Clamps (2X)
 Pulling Rings (4X)
 O -Ring
 Bucket with Water
 Screw Driver
 Hammer
 Key
It shall be as per manufacturer recommendations.

5.3 MATERIAL STORAGE AND HANDLING

5.3.1 Pipes and Fittings shall conform to JERES-S-070 Para. 6.2 & 6.3 for
storage and preservations
5.3.15.3.2 The material handling, fabrication and installation of RTR Pipes
shall be followed as per vendor recommendations.
5.3.25.3.3 Incoming Inspection shall be carried out for shipments of Bond
strand Pipe and fittings for abuse in shipping. Broken Pipe bundles,
crushed fittings boxes, scratched and gouged pipe with crushed or spilt
ends are evidence of such abuse shall be checked.
5.3.35.3.4 Do not throw or drop pipe and fittings, protect from all types of
impact. Bond strand may be damaged by careless handling,
sometimes without exhibiting visible effects on the pipe surface.
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5.3.45.3.5 Pipe or pipe bundles may be stored for extended periods in

stacks up to four feet high. Pipe stacks must have supports or blocks to
prevent rolling or slipping of the stack.
5.3.55.3.6 Pipe and spool assemblies shall be spaced no greater than 20
feet and within 2 feet of the pipe end.
5.3.65.3.7 For work on the pipe, such as cutting, preparing ends, or
cleaning, two point support is required for 20 foot lengths and three-
point support for 400 foot lengths and height will be 100 mm minimum
from the ground level.
5.3.75.3.8 Care shall be taken not to place the supports under bells,
spigots or factory made joints.
5.3.85.3.9 Lifting slings should be made from woven nylon or canvas and
should be minimum of 3 inch wide

5.4 QUALIFICATION OF INSTALLER

 5.4.1 All Installer must be successfully qualified to requirements prior to Formatted: Bulleted + Level: 9 + Aligned at: 0" + Tab after:
0.38" + Indent at: 0", Tab stops: 1.06", List tab + Not at
 performing joining operation. 0.38" + 3" + 4.75" + 6"

5.4.2 Installer must be trained and highly experienced in related to this

RTR Pipe installation.
o 5.4.3 Installers shall be certified in accordance with JERMS-L-1034.
o 5.4.4 Installer must have ability to ensure quality of project requirements.
5.4.5 All workers engaged in RTR Pipe installation must be
skilled as well as trained.

5.4.1 Qualifications of Installer shall be as per JERES-S-070 Para. 9.4 and

company guideline document (QLT-F-A4000 RTR installer JCC
Guideline) for qualification & issuance of JCC for RTR installer.

5.5 PIPING AND FITTINGS MATERIALS TRACEABILITY

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5.5.1 All components shall be permanently marked for proper identification

as per JERMS-L-1029 Para 13.1 & 13.3. All required marking shall
remain legible under normal handling and installation practices. The
marking shall include the following:
- Manufacturer's name or trade name, and identification code
- Temperature rating
- Nominal diameter
- Cell classification in accordance with industry standards (from
Section 6 of this specification)
- Inspection and hydrotesting mark
- Date and shift of manufacture
- SAMS stock number (if applicable)
- Purchase Order number
- Flange designation code

5.5.2 Small fittings and flanges that cannot be marked shall be tagged.

5.55.6 FABR
ICATION

Refer Manufacturer recommendations.

Fabrcation shall be done as per JERMS-L-1029 and Manufacturer

recommendations.
5.5.1 JOINT ASSEMBLY

5.5.1.1 Before joining pipe, end protection from both the male and
female pipe end must be removed.
5.5.1.2 Clean the grooves and sealing surface of both female and male
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Pipe end using dry rag or paint brush.

5.5.1.3 Brush, or rub a layer of joint lubricant into the O-ring and key
grooves of the male pipe end.
5.5.1.4 Lubricate the inside of female pipe end and locking key groove
with ample amounts of lubricant.
5.5.1.5 Keep lubricated surface clean and free of sand and dirt as
contamination is likely to interfere with joining and sealing
.Proper lubrication of O-ring and joint surface is done to avoid
cutting the O-ring or rolling it out of place during assembly.

5.5.2 PIPE SPIGOT INSERTION

5.5.2.1 Pipes with bell and spigot or coupling joints should be

assembled in the trench.
5.5.2.2 Align the male pipe end against the female pipe end already in
place for a straight concentric entry.
5.5.2.3 Deflect the joint to conform to the actual horizontal and vertical
alignment of Trench only after the joint is fully assembled in the
straight position.
5.5.2.4 Rotate the female pipe end or fitting in such way that its keyhole
is in proper position to drive the keys.
5.5.2.5 Place the band clamps just behind the female end or coupling
and the other about 1.5 meters from the male end. Put the
pulling rings at position of 3 or 9 O’clock.
5.5.2.6 Connect the power pulls to pulling attached to the band clamps
on either side of the pipe and pull the pipes together. Tighten the
power pulls evenly on both sides so the O-ring enters smoothly
and without being pushed or rolled out of its groove.
5.5.2.7 Insert the male pipe end until the scribe mark is in line with the
leading edge of the female pipe end. To prevent slipping of the
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band clamps, one may choose to use rubber pads under the
band clamp. Over tighten of band clamps are not allowed
otherwise it will crush the pipe.
5.5.2.8 After insertion check Pipe concentricity and uniformity of entry.
5.5.2.9 Keep keys ready for insertion when scribe mark is about 6 mm
away from the leading edge of the female pipe end.
5.5.2.10 Check the Pipe alignment again by looking along the pipe and
aligning the scribe mark on the male Pipe end with the edge of
the female end.
5.5.2.11 Drive the key by using wooden hammer only until you can see
its leading end through the insertion hole. Also remove power
pulls and band clamps

5.6 TAPER ADHESIVE BONDED JOINTS

Refer Manufacturer recommendations.

5.6.1 All pipes, joints, fittings, couplings, and spools, supplied under this
specification, shall be identified by cell classification system from the
standards listed in Section 6. Equivalent cell classifications by other ASTM
standards are also acceptable.
5.6.2 The product shall meet the performance requirements of Section 9
of this specification.
5.6.3 Pipe and couplings shall be filament-wound using polyester, vinyl
ester or epoxy resin and fiberglass reinforcement.
5.6.4 Resin System
Resin shall be suitable for the services specified, and shall be noted by the
vendor in his proposal. The resin system used for the interior liner, the
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structural wall, fittings, and adhesives, shall be polyester, vinyl ester or epoxy,
with suitable curing agents so that it meets the performance requirements and
temperature limits in this Specification.
5.6.5 Glass Reinforcement
The structural wall reinforcement shall be of commercial-grade glass fiber,
suitable for the services specified in the Purchase Order, treated with a
compatible binder and coupling agent.
5.6.6 Fillers
Siliceous sand may be used as filler as specified in cell classification.
Siliceous sand shall conform to ASTM C33, except that the requirements for
gradationneed not apply.
5.6.7 Additives
Resin additives such as pigments, dyes or coloring agents may be used,
provided they do not detrimentally affect the performance of the pipe. The
pipe shall contain a UV inhibitor if requested on the Purchase Order. Pipe and
fittings that will be exposed to sunlight when installed, shall contain UV
inhibitor.
5.6.8 Reinforcing Fiberglass Ribs
Pipe sizes 2600 mm (102 inch) and higher may be manufactured with
reinforcing fiberglass external ribs to achieve the required stiffness.
5.6.9 Joint Types
The pipe shall have one or a combination of the following joining systems that
shall provide for fluid tightness for the intended service condition.
a) Unrestrained Joints
1. Gasketed bell-and-spigot
2. Gasketed bell and bell coupling for use with spigot and pipe
b) Restrained joints
1. Bell-and-spigot, adhesive bonded
2. Butt-and-wrap, with reinforced overlays
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3. Non-commercially available special joints or any proprietary joints

shall have a prior approval from the chairman of Plumbing and Utilities
Standards Committee.
5.6.10 Adhesives and solvent cleaners
Adhesive for bonded joints shall be of a material suitable for the services and
design conditions specified. Cleaning fluids/agents and adhesives shall be
compatible with the resin used to manufacture the pipe, pipe seals and
gaskets.
Adhesives shall be provided in a self-contained kit with all necessary
materials and instructions. The adhesive kit shelf life at 38°C shall not be less
than 9 months from the date of shipment. Adhesive kits shall indicate the
required storage conditions and date of expiration of shelf life. Adhesives shall
be suitable for use in a 48°C working environment.
5.6.11 Flexible Elastomeric Seals and Joint Tightness
The chemical composition of the flexible elastomeric seals shall be
compatible with the type of service and environment to which it will be
subjected.
5.6.12 Fittings
Flanges, wyes and other drainage fittings may be compression-molded,
manufactured from mitered section of pipe, or manufactured by the filament
wound process, using thermosetting polyester, vinyl ester or epoxy resin and
fiberglass reinforcement such that the resistance to chemical attack and the
temperature rating are equal to or better than that of the pipe. All such fittings
used for drainage shall be of the drainage type, having a smooth interior water
way of the same diameter as the piping served and shall be compatible with
the type of pipe used.
5.6.13 Except for compression-molded fittings, all pipe, fitting, and flange surfaces
that are exposed to the fluid shall have a smooth, uniform, resin-rich liner with
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a thickness of 0.51 ± 0.13 mm (0.020 ± 0.005 in). The interior liner shall be
reinforced with either nonwoven polyester fibers or glass veil surfacing mat.
Polyester or glass veil liner reinforcement is not required on 100 mm (4 in)
and smaller fittings at the mitered joints, provided all gaps at the joints are
completely filled with epoxy resin to act as an effective corrosion barrier and
to prevent the presence of any exposed glass fibers.
5.6.14 All machined or cut surfaces shall be post-coated with catalyzed resin except
for bonding surfaces for field joints and mechanical fiberglass threads. Post-
coating shall be performed within four hours of machining or other surface
preparation.
5.6.15 Adhesive-bonded joints, if any, shall be bell and spigot type and shall not
require a field-applied overwrap to develop the required strength.
5.6.16 Flanges, if provided, shall be flat-faced, or flat-faced with a confined O-ring
gasket groove.
5.6.17 All pipe, fittings and flanges for a particular new installation shall be
manufactured or supplied by the same Vendor to avoid incompatibility due to
intermixing of products from different manufacturers.
5.6.18 Threads shall be per ASME B1.20.1 and shall conform to the requirements of
ASME B31.3, paragraph A 314.2.2. Threaded joints are not permitted in
piping manufactured using any kind of fillers, such as reinforced plastic mortar
piping (RPMP)

5.7 INSTALLATION AND REQUIREMENTS

5.7.1 For handling, joining and installation, vendor recommendation to be

respected and used.
5.7.1 For handling, joining and installation use JERES-S-070 and vendor
recommendation to be respected and used.Defective material at site shall be “
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quarantine & the client shall be informed “ & after which this shall be disposed
as TRGC company procedure.

5.7.2 Upon receipt of the pipe shall be subjected to visual inspection for any damage
during transit, and if defects are found the same shall be intimated to TRGC.
5.7.3 Pipes shall be placed near the excavated trench leaving a minimum safe
distance from the top edge of it as per JERES-S-070.
5.7.4 As RTR Design, support from surrounding soil shall be provided in
accordance with JERMS-L-1029, JERMS-L-1034 & JERES-S-070.
5.7.5 Pipe joined into longer lengths or pipe and fittings in subassemblies should be
lifted with web slings with enough lift points to avoid excessive bending and
dynamic flexing as per JERES-S-070.
5.7.6 Position the pipe on timbers across ditch. Block into position to hold alignment
and prevent lateral movement. For larger diameters, the use of a winch is
recommended to assemble and hold joint as per JERES-S-070.
5.7.7 Joint the pipe sufficiently in advance of the pipe lowering operation, so that no
movement of the pipe will take place at location where joints are being cured.
Pipe spools will be fabricated at above ground to a maximum length by
considering the erection feasibility and the same will be lowered on sand bags
having 150mm height in to the trench, placed at equal intervals as per
JERES-S-070.
5.7.8 With crane or manpower, raise the pipe slightly to remove the timber support
placed below the pipe. While lowering the pipe into the ditch, do not drop or
lower suddenly. Repeat the above operation for each support. Use rope or
webbed sling for lifting pipe as per JERES-S-070.
5.7.9 Suitable foundation support or padding extending shall be provided from the
end the end of encasement and also adequate protection shall be provided in
the road crossing as per project documents/vendor recommendation & as per
JERES-S-070.
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5.7.10 All inspection formalities will be completed prior to backfilling.

5.7.11 Respective test packs will be made and submitted for approval as per the
ITP.
5.7.12 The system will be hydro tested after approval of the respective test pack by
TRGC/ SATORP.

5.8 THRUST AND ANCHOR BLOCK INSTALLATION

5.8.1 Thrust and Anchor Block shall be installed as per the engineering standard
and drawings.
5.8.2 The structural concrete for the thrust and anchor block shall be used as per
approved for the underground foundation.
5.8.3 The pipe shall be tested or placed in service when concrete is fully cured.

5.8.4 Thrust blocks (Company Library Drawing JERSD-S-1004, for reference only)
shall be placed at every change in direction for thermoplastic and RTR piping
with the following exceptions:
Exceptions:
a) Thrust blocks may not be necessary for piping in gravity flow systems.
b) Thrust blocks may not be required for 100 mm nominal pipe size and
smaller piping with restrained joints, as defined in Sections 11 and 12 of
this Standard.
5.8.5 If thrust block is required for RTR piping and thermoplastic piping in
accordance with paragraph 18.1 of this Standard, a thrust resistance shall be
provided prior to hydrostatic testing by temporary wooden supports.
Alternatively, the Contractor may choose to place concrete thrust blocks
before hydrotest at the risk of having to remove and replace any thrust blocks
on leaking components.
5.8.6 Thrust blocks shall not cover thermoplastic and RTR piping joints.
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5.8.7 Plastic pipes such as PVC, UPVC, CPVC, RTRP, HDPE, PP etc shall be
protected from contact with concrete by tape wrapping. Use JERMS stock
number for tape wrap 09-966-251/254/257 or equivalent.
5.8.8 At the edges where a thermoplastic or an RTR pipe or fitting enters or leaves
a thrust block, it shall be wrapped with neoprene wrapping that will protrude
slightly from the block. The thickness and the width of wrap shall comply with
Table 4 of this Standard, unless the manufacturer requires more than one
piece of wrapping.

5.9 BEDDING AND BACKFILL

5.9.1 Bedding, backfilling and concrete supports shall be done as per the civil
drawing.
5.9.2 Bedding in the pipe zone should be sand and must not include rocks larger
than 3/8” or sharp rocks of any size in direct contact with the pipe.
5.9.3 Sand bedding under the pipe should be a minimum of 25% of dia of pipe or
150 mm; sand shall pass a 3/8” screen and not more that 15% shall pass a
#200 sieve.
5.9.4 Accurately grade the trench bottom and sand bed to provide uniform bearing
support for each section of pipe along its entire length, a shallow depression
for
bells and couplings are required. The grade shall have no abrupt changes in
direction or slope except at fittings.
5.9.5 Do not cover the pipe joints until all required pressure tests are performed.
5.9.6 Initial back filling zone extended from the bedding to a minimum of 150 and
above this the crown of pipe shall be achieved.
5.9.7 Sand shall be uniformly compacted around the pipe with special care given
to the bedding beneath the haunches of the pipe. Sand bedding and backfill
should extend a minimum of 200mm above the pipe or clean / sweet sand
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bedding of 300mm thick above pipe, which will be compacted using water
compaction.
5.9.8 Backfill shall be deposited in 200mm maximum layers to a point at least two
feet above the top of the pipe, each layer being compacted with suitable
tamper.
5.9.9 Mechanical compactors may be used for compaction, provided the harmful
shock loads are not transmitted to the pipe wall.

5.9.1 The clean sand bedding shall be compacted per Section 10.7.2 of this
standard.
5.9.2 Within 300 mm of the top of the pipe, backfill shall be hand tamped, or a
board shall be used to protect the pipe from damage from vibratory plate
compactors.
5.9.3 Backfill above 300 mm sand cover in Non-Traffic area shall be on site
excavation or borrowed materials that meet the following conditions:
a) Not more than 3% organic or decomposable material.
b) No debris.
c) A maximum particle size of 150 mm or one-half the lift thickness, whichever
is smaller.
d) Minimum compaction shall be per down Table of this Standard.
Minimum Compaction
Non-traffic Areas Traffic Areas
65% relative density 85% relative density
per ASTM D4253/ASTM D4254 per ASTM D4253/ASTM D4254
or or
90% of maximum 95% of maximum
density per ASTM D698 density per ASTM D1557
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5.9.4 Backfill above the 300 mm sand cover in Traffic Area shall meet the
requirements of Section 22.3 of this Standard, except in the final 300 mm of
the backfill. This part of the backfill that is the base of the asphalt pavement
shall meet Class B base material as defined in JERES-Q-006, Table A.
5.9.5 Any sheeting and shoring shall be gradually removed as the backfill
is placed. All voids under and behind sheeting shall be filled as sheeting is
withdrawn.
5.9.6 Sheeting shall be cut and left in place where damage to the pipe may
occur or failure of the trench walls may cause damage or failure of
adjoining buildings or structures.
5.9.7 The pavement base course shall be of the same depth and material as the
original base course. The edge of existing pavement and the base course
shall be primed. The surface course shall be identical to the original
surface course. The patch shall be rolled in both directions with a 5-ton
roller so it is compacted to 96% of Marshall density in accordance with
ASTM D1559.
5.9.8 A bedding layer of clean sand 150 mm in depth is required for all trenches.
The sand shall be free of debris and rocks and compacted to at least 70%
relative density in accordance with ASTM D4253 and ASTM D4254.
Compaction by water flooding is allowed for clean, freely-draining sand
provided the excess water is continuously collected in sumps and pumped
out of the trench. Maximum and minimum densities of a representative
bedding sample shall be determined in accordance with ASTM
D4253 and ASTM D4254 for all locations. In-place density and moisture
content methods and frequency of testing shall be in accordance with
JERES-A-114.

5.10 VALVE INSTALLATION AND BOLT TIGHTENING PROCEDURE

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5.10.1 Bolt installation and tightening shall be executed according to approved

design drawings, applicable code, standards, project specifications,
referenced procedures and general basic practice for said works.
5.10.2 Appropriate lubricant will be applied to the entire bolt threaded area, nuts and
its contact face.
5.10.3 Thread lubricants shall be suitable for the operating temperature of the
system in accordance with JERES-L-610. Precaution shall be taken to avoid
contact between lubricant and the gasket or its seating surface
5.10.4 Flange face will be thoroughly cleaned until all rust and burrs are removed.
Care shall be taken to the gasket seating surfaces.
5.10.5 Gasket surfaces on flange faces will be thoroughly inspected.
5.10.6 All nuts are to be cleaned for free running thread and the face of the nut that
contact the flange surface will also be even and flat with no burrs or high
spots.
5.10.7 Bolts shall be installed on the bottom half of the flange.
5.10.8 Gaskets shall be inserted and located at the center of the flange assembly.
5.10.9 Gaskets shall not be held in place with tape during flange alignment. A heavy
grease or gasket cement can be used, if necessary. Note: Never use heavy
grease or gasket cement when the pipe medium is compressed gas or air.
5.10.10 Verify alignment tolerances for mating flange faces of pump and compressor
are in accordance with JERES-L-610.
5.10.11 The required precaution will be taken with large diameter spiral wound
gasket to avoid “springing” the windings.
5.10.12 For temporary spools and blind flanges, temporary gaskets can be used.
5.10.13 All flanged joints will be snugged up squarely so that the entire flange faces
bears uniformly on the gasket.
5.10.14 Dimensional Tolerance of the gap and offset between flanges shall be in
accordance with “specification for bolt and torquing and tensioning of piping
system”.Stud bolt tensioning shall be performed on all bolting 6 inch and
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longer.
5.10.15 The remaining bolts will be installed. All bolts shall extend completely through
their nuts.
5.10.16 At least one (1) complete thread or 3mm which ever is greater shall be visible
from the back side of each nut.
5.10.17 All hydraulic torque wrenches shall have calibration stickers. Records
shall be If a tensioning device is to be used, the stud shall protrude 1 bolt
diameter longed the nut to allow attachment of tensioning device. The
other end of the stud shall extend three threads or 9mm (which ever is
greater) past the nut.
5.10.18 Prior to Hydro test NSH test Engineer/Inspector should identify the flanges
which require torque before test and it to be completed along with the
category ‘A’ items Punch.
5.10.19 Flanges which is marked in the test Packages should be torque except test
limit and those flanges where temporary gasket is installed. (control valve,
and other inline items)
5.10.20 After Hydro test torquing will be done at the test limits and to be inspected.
5.10.21 Copy of bolt torque sequential order and rotational order is attached along
with JERES-L-610.
5.10.22 The table of torque values and bolting category is attached along with
JERES-L-610.
5.10.23 Hand tightening of the bolts will be done. One full thread will be kept visible
beyond the nut.
5.10.24 The torque values of bolt tightening shall be done as per JERES-L-610.
5.10.25 Bolt torque will be done as per the sequential order mentioned in the
specification JERES-L-610 in three passes.25% of the target torque value
will be applied in the first pass, 50% of the second pass, and 100% in the
third pass.
5.10.26 Once the final torque value is reached, the bolts will be tightened in
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clockwise direction as per the rotational order mentioned in the specification

JERES-L-610, followed by a second round in the counter clockwise
direction.
5.10.27 After torque, ends of studs will be assign specific color identification to
identify torque flanges.
5.10.28 Inspection will be done as per ITP: SA-JER-DSAAA-TRJR-509140att01.
5.10.29 Flanges to be tightened by torque shall be identified by flange welding joint
Number.
5.10.30 When Hydraulic equipment used for bolt tightening the equipment catalog
to be issued in advance for review and approval.

5.11 HYDROTEST AND FLUSHING PROCEDURE

5.11.1 Unless prevailing conditions or regulations require full backfilling of the

piping prior to the hydrotest, underground piping shall be partially backfilled
with all joints exposed during the hydrotest. The exposed joints shall be
shaded from direct sunlight, and the hydrotest shall be performed so that the
temperature of the thermoplastic piping material or the temperature of the test
water does not exceed 40°C during the test period. If the test water is not
available at or below 40°C, the resulting hydrostatic test pressure shall be
calculated at the available test water temperature in accordance with the
respective ASTM standards.
5.11.2 Hydrostatic testing fluids shall be as follows:
a) Potable water (drinking water and raw water) piping systems shall be
hydrotested with fresh potable water as defined in JERES-S-040.
b) Other utility piping systems shall be hydrotested with potable water, well
water or seawater.
5.11.3 No thermoplastic piping shall be pressurized until it has cured for 24 hours at a
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surface temperature of 10°C or higher, or for 48 hours at a surface

temperature below 10°C.
5.11.4 No adhesive-bonded RTR piping shall be pressurized until it has cured in
accordance with the manufacturer's instructions.
5.11.5 The test pump shall be placed on firm ground away from the piping. The
pump and the piping system (piping and equipment) shall be protected from
overpressure by relief valve(s) of adequate capacity set at 5% above the test
pressure or a maximum of 170 kPa (25 psig) above the test pressure for
pressure piping systems. The relief valve(s) shall be tested, dated, and
tagged within one week prior to the test. Sizing of relief valves used for testing
shall be in accordance with JERES-A-004.
5.11.6 Requirements of pressure gauges and pressure recorders for pressure piping
systems, calibration intervals, and calibration certificates shall be in
accordance with JERES-A-004. Calibrated and tagged relief valve(s) may be
used as the pressure test instrument upon written approval of the Manager,
Inspection Department.
5.11.7 Gravity sewers shall be tested from manhole to manhole, or manhole to sump
inlet. The upstream manhole may be tested at the same time.
5.11.8 Lines whose joints have been backfilled shall be tested at the following
pressures for 24 hours. Lines whose joints have not been backfilled or are
above ground shall be tested at the following pressures for 4 hours:
a) Irrigation piping downstream of the pressure-reducing valve and/or
backflow preventor: 690 kPa (100 psig).
b) Water distribution piping network, as defined in JERES-S-040, and fire
hydrants connected thereto: 1035 kPa (150 psig) or 345 kPa (50 psig)
above the maximum operating pressure, whichever is greater.
c) Dedicated firewater systems (except building firewater systems as covered
in JERES-S-050) and fire hydrants connected thereto shall be tested in
accordance with JERES-B-017 and JERES-A-004.
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d) Sanitary sewer and storm water force mains: 1035 kPa (150 psig) or 345
kPa (50 psig) above the pump shut-off head, whichever is greater.
e) Gravity sanitary sewer pipe tested separately: a column of water equivalent
to the rim elevation of the upstream manhole.
g) Gravity storm water sewers and manholes not a part of an oily water sewer
system: none, unless called for in the project specifications.
h) Nonmetallic piping in non-hydrocarbon process applications: 1035 kPa
(150 psig) or 345 kPa (50 psig) above the maximum operating pressure,
whichever is greater.
5.11.9 Plumbing and utility systems within buildings shall be tested in accordance
with the Uniform Plumbing Code (UPC), with the exceptions as listed in
JERES-S-060.
5.11.10 Building firewater systems shall be tested in accordance with JERES-S-050.

5.12 SAFETY

5.12.1 NSH Safety Supervisor shall carry out the safety site inspections to ensure
that safety requirements laid out in the safe work plan are followed during the
testing.
5.12.2 NSH Safety Manager / Supervisor shall review Safety Action Plan and secure
work Permit if necessary prior to start of any activities Job safety analysis will
be strictly followed as per attachment.
5.12.3 Equipment, tools and materials inspection. All equipments for testing shall
have to be inspected by NSH Safety Manager / Supervisor prior to forwarding
to TR Safety Department inspection prior to use at site to ensure their safe
worthiness at work. The inspection reports shall be kept for record.

5.13 Risk Assesment

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The requirements of the project helath and safety plan shall prevail in respect of
safety requirements for those involved in the Assembly and Installation of RTR
pipes.
The QAlQC manager will ensure that only persons competent to undertake
inspections shall be allowed to do so, having regard to the fact that some
inspections and maintenance activities may only to be undertaken by third
parties organization.
In particular, it is the responsibility of the Manager to consider the following:
 Risks
 Training and Information

5.13.1 The following risk assessments and does not take the place of the task risk
assessment for the activity concerned.

Risk Assesment
Task Hazard Person at Controls Person
Risk Responsible

Material Personnel Personnel Follow safe Task

handling injury due to assigned working Supervisors
sharp edged for the procedures. and
objects while task Conduct Foremen
1. handling trainings and
toolbox
meetings.
Practice JSA
and STA.

Fall hazards Personnel Properly Task

while loading assigned secure the Supervisors
/ unloading for the load and
/carrying task Foremen
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Work under Personnel Never allow Task

suspended assigned any body to Supervisors
load for the work under and
task the load Foremen

Accidental Personnel Proper flag Task

hitting due to assigned man and Supervisors
vehicular for the inspection of and
movement task vehicles. The Foremen
vehicle
should have
back up
alarm and
flash light
Cutting or Inhaling Personnel A dust mask Task
problems, skin assigned for covering nose Supervisors
Grinding
problems the task and mouth, a and Foremen
2. pair of safety
glasses, gloves
and overalls.
Usage of Harmful upon Personnel In case of Task
inhalation and assigned for contact with Supervisors
3. Resins and
contact with the task eyes, rinse and Foremen
hardener. skin. immediately
with plenty of
water and seek
medical advice.
Wear protective
clothing, gloves
and eyes/ face
protection.

Test blind Improper Personnel Select proper Task

4.
preparation blind assigned blind Supervisors
and selection for the according to and
installation causing task the test Foremen
overpressure requirements
and rupture
of line during
testing
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Water filling Slippery floor Personnel Use proper Task

5.
surface assigned drying agents Supervisors
for the and
task Foremen

Pressurizing Leakage in Personnel Use proper Task

6.
flanges assigned drying Supervisors
during for the agents. and
pressurizing task Foremen
causing
slippery
hazards

Over Personnel Control and Task

pressure assigned properly Supervisors
causing for the monitor the and
explosion task pressure. Foremen

Over Personnel Control and Task

7.
Holding pressure assigned for properly monitor Supervisors
causing the task the pressure. and Foremen
explosion

Pressure Over Personnel Control and Task

8.
releasing pressure assigned for properly monitor Supervisors
causing the task the pressure. and Foremen
explosion

Cleaning Slipping Personnel Use proper Task

9.
flushing and hazards assigned sand to avoid Supervisors
drying for the wetness and
task Foremen

Noise Personnel Enclose the Task

hazard assigned noise source Supervisors
for the and use and
task hearing Foremen
protection
devices
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Flying Personnel Use face Task

particles assigned protection Supervisors
causing for the and
bodily injury task Foremen

Dust Personnel Use Task

generation assigned respiratory Supervisors
for the protection and
task Foremen

5.14 Training and Information

Ensure that those involoved in calibration of inspection measuring and test

equipment have access to and familiarity with project safety procedures.

Training and Information as follows:

Training and information

Docement/ Procedure Supervisor and QC responsible Operator

5.14.1 Site Induction/ Copy of document and trained Copy of document

basic safety training and trained

5.14.2 manufacturers Copy of document and trained Copy of document

specific operating and trained
instructions

5.14.3 appendix 18 site Access to document & Part of continued

HSE Plan: toolbox knowledge to content training
content:- handtools,
electric tools,
electricity, plant and
equipments, permit to
work
5.14.4 Appendix site
HSE Plan. Site Safety Access to document & Part of continued
Specifications knowledge to content training