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Misr Sons Development S.A.

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Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 1 of 9

Contents:1. Scope. 2. References. 3. Handling & Storage. 4. Installation. 5. Hydrostatic field test. 6. Deflection measurement

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 2 of 9

1. Scope :The procedure deals with handling, laying and testing of under ground pipe of GREV of bell and spigot joint sealing by means of double O-ring elastomeric gasket and a locking key made of round or rectangular bars which shall be inserted in a groove both bell and spigot. 2. Reference :2.1 Project specification 10056-9-3PR-G01-0001 99999-9-3DS-P72-02026 99999-9-3SS-PP00-00001 99999-9-3SS-PP00-00002

3.Handling & storage: 3.1 Storage and handling shall be done with care to avoid any mechanical Damage to the GRE pipes and fittings. They should never be thrown or dropped to the ground nor set on sharp objects. 3.2 3.3 Storage surface shall be as level and as firm as possible and clear of rocks and solid objects that might damage the pipes. GRE pipes and fittings may be stored outside providing that; - Storage areas, perfectly flat. - Storage is not done on hard soil Adequate support shall be set using wooden beams of proper size and length. - Pipe are supported in a way that prevent any distortion of the pipes. Intervals shall not exceed 3mt and minimum of 1.5 mt.

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 3 of 9

3.4

Pipes shall be stored in separate stock piles with limited height of 2-3mt according to there class and nominal diameter but not more than 3 pipes high. Wooden wedges to avoid sliding of whole pipe stock shall be placed on both sides of first layer in the stock on the timber bearer. Pipes of larger than 1400 mm dia shall not be stocked.

3.5 3.6

The protective end covering shall be left in place until the time of installation. Rubber gaskets, shall be stored in a clean cool area shaded from sun in their original packing until they are ready for use. Lubricants for rubber gaskets, packed in drums shall be stored at temperature raging between 30C & 40C

3.7

Material for on site laminations ( resins and other chemicals.) shall be stored in the original drums and packages, in doors, in a dry, dark and ventilated ambient at temp-of approx 20 C. Packages shall not be opened if the product is not used within short time. Raw liquids shall always be kept away from naked flames or sources of heat

3.8 3.9

Small diameter pipes not exceeding 60 kg, shall be unloaded and handled by hand. Mechanical unloading and handling shall be adopted for pipes heavier than 60kg. Nylon or canvas slings shall be used for the purpose and pipe shall be balanced while lifting. (No steel cables or chains shall be used).

4. Installation : 4.1 As soon as excavation trench is dry and ready for handling the pipe line, pipe lowering activity shall start, and jointing shall be made inside the trench. Pipe and pipe components shall either be lowered manually or mechanically depending upon pipes weight. Pipes weighing up to 175 kg may be lowered

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 4 of 9

manually by means of two nylon or canvas slings. While mechanical lowering shall be used for larger diameter pipes. 4.2 Before lowering the pipes into the trench, the top 2-3 cm of compacted bedding shall be lightly racked and small "bell" holes shall be dug under each joint location such that the pipes does not rest on the joints. In other words the bedding material shall provide continues support over the entire length of the pipe excluding the joints locations. 4.3 Before jointing, the grooves of sealing surface of female end shall be thoroughly cleaned. Any projections that may damage the O- ring during insertion shall be removed. The O- ring shall then be positioned and fitted correctly over the spigot into the groove. The surface of O- ring shall then be lubricated as well as internal surface of the bell using vegetable based soft soap. 4.4 Assembly of bell and spigot ends may be made by hand .However for pipes of diameters> 150 DN a come - along type puller shall be used. The come - along type puller shall be done as following; Two nylon slings or ropes shall be tied around both the bell section and the spigot end to be installed. leave the slings slightly loose. Slings on either sides of the pipe shall be connected with jack pullers. The slack on both sides shall then be taken up and continue jacking the spigot end into the bell until the end of the bell edge reaches the insertion limit marked on the spigot end. The position of gaskets shall be checked from inside if the size of the pipe. allows it.

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 5 of 9

4.5

For large diameter pipe ND> 1000 and as an alternative to come - along jack, the bucket of the backhoe may be used to push the pipe into the previously installed section, providing that an appropriate wooden bulk head be between the pipe end and the bucket.

4.6

After assembly the position of the gaskets shall be checked from the inside if the size of the pipe allow it.

4.7 4.8

In case of double o- ring, sealing test shall be performed before starting to insert the locking key / or keys. Sealing test shall either be done by water or compressed air, with 1.5 times the working pressure but not exceeding 5 bar. Duration of the test shall be for 5-100 minutes. In case of no pressure losses or for any visible leakage of the joint, the testing apparatus shall be removed and the test nipple be plugged. In case of failure during test , the bell and spigot joint shall be stripped, Cleaned, realigned and assembled, with new 0- ring if the original is damaged.

Note: - Pressure test apparatus shall consist of, hand pump or air compressor, pressure gauge, 3 way valve (to entrap the air from the container), relief valve and fittings for the pressuring system (All items included in the pressure test apparatus shall be of such type to with stand the test limits). 4.9 For inserting the lock key the first 15 - 20 cm shall be lubricated lightly, and the beveled end shall be rested against the inside surface of the bell. Installation shall be made using a plastic hammer or a piece of wood to tap the key all the way inside, until it rests against the first part of the key. 4.10 Pipe installation shall be checked prior to backfilling including dimensional, location , orientation, supports , thrust blocks and link seals.
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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 6 of 9

4.11 Valve boxes:Valve in buried section shall be protected by valve box and shall also be supported. - All casing end seals shall be installed at the outside of wall penetration of the valve box to protect the valve box from flooding and heavy enough to prevent floating. 5. Pressure testing of GRE pressure pipe line : 5.1 The following points shall be carefully checked, before testing:5.1.1 Length of test portion shall not exceed 500 m. 5.1.2 All punch items included in QC form punch list had been eliminated, examined and confirmed. 5.1.3 Pipe haunches and partial back filling shall be checked for compaction in order to avoid displacement of the line during testing. As alternative sand bags may be used to restrain the fitting. 5.1.4 All joints shall remain uncovered during test, in order to be visible for inspection during test. When testing pressure pipes back filling shall continue to 0.6 m above the pipe while leaving the top 1/3 of the joints exposed to allow for visual determination of any leak. 5.1.5 All testing apparatus are available and operational. 5.1.6 Open ends shall be sealed temporarily with end caps (GRP, steel or Cast iron).Water inlet shall be placed at the bottom of the end cap at the low end, and outlet at the top at the high end. Vents at appropriate locations shall be provided to allow escape of trapped air. 5.1.7 Special provision for bracing test ends shall be made for thrust blocking

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 7 of 9

the ends relative to thrust force created due to internal pressure .Jacks shall be placed between pipe ends and blocks to permit restoring the test end caps to its original position if the blocks starts to move. 5.1.8 The last pipe length shall be wedged on both sides and at the top and bottom to prevent lateral and vertical movement. Sand bags may be used for this purpose. 5.2. Hydrostatic field test: 5.2.1 Filling line & static leak :5.2.1.1 The line shall be filled slowly from the lower part evenly with water of velocity 0.3 m/s max .with air release valves installed at the high points. 5.2.1.2 When the line is completely fill, all vents and valves shall be closed, and visual control along the run of the line shall be made to detect any leakages. In case of leakage the line shall be emptied and necessary repair shall be carried out. 5.2.2 Stabilization of the pipe line :5.2.2.1 After filling the line, the pressure shall be increased up to the design pressure. The increase of pressure shall not be greater than 1 bar every 10 minutes for ND < 500 mm and 1 bar every 5 minutes for ND > 500 mm maintained. 5.2.2.2 The pressure shall be maintained up to a maximum of l2 hrs . If no visible leakages possible pressure drops shall be balanced by switching on the pumping system. 5.2.2.3 The stabilization phase shall be considered finished when no pressure variation occur for at least 2 - hours without water integration.

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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 8 of 9

5.2.3 Pressure testing :5.2.3.1 Pressure shall be increased until test pressure value. Both pressure and temperature at the beginning shall be recorded. 5.2.3.2 The line shall be kept at the test pressure value for a time not less than 2 hours. 5.2.3.3 At the end of a/m 2 hrs both pressure and temperature value shall be Recorded. 5.2.4 Acceptance of the test :The hydraulic testing shall be considered positive if at the end of the 2 brs one of the following points is achieved :During the period of the hydraulic test the pressure shall stay stable. No leakage are visible in any point of the pipeline. Change in pressure between the beginning and the end of testing is due to either change of temperature or due the pressure of air in line. 6) Deflection measurement: 6.1 Maximum recommended allowed long term defection in GRP pipes is 5% (which is measured as percentage reduction in vertical diameter after installation and backfilling). 6.2 For pipe sizes 800 mm and larger, the vertical pipe ID shall be measured by using a telescope micrometer 3 - 4 mt intervals since human entry is possible. For smaller sizes, a wooden disk (pig) whose outside diameter is equal to the main acceptable deflected pipe ID shall be pulled through the
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A.M.S

Misr Sons Development S.A.E


Hassan Allam Sons Project. : Subject : GRE (UNDER-GROUND) PIPE ERECTION PROCEDURE ( BALL AND SPGOT ENDS) Doc. No. WP-GRP-No.1.3

Rev : (2) Date : 12/02/2007

Page 9 of 9

pipes.(wooden pig shall have eye hook on both sides to attach the pulling rope) If the "pig" passes freely it means that pipe deflection have not exceeded the limit set by the pig OD. If positive deflection is measured, this indicate an adequate compaction in the pipe zone. Accordingly backfill shall be removed to about 1/3 of the pipe ID from the trench bottom and shall re compact the backfill in stages up to the top of the pipe zone. After this rectification, the deflection shall be measured again.

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A.M.S

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