WORK INSTRUCTION RTR PIPING SYSTEM

TABLE OF CONTENTS
Pages

Issue / Revision Record 3

1.0 Scope & Purpose 4

2.0 References 4

3.0 Definitions & Acronyms 4

4.0 Responsibilities 5

5.0 Procedure 5-8

6.0 Supporting Documents 9

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WORK INSTRUCTION RTR PIPING SYSTEM

ISSUE / REVISION RECORD

Issue Revision Paragraph Description Date

1 0 All Issued for approval 17-Dec-2011

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

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WORK INSTRUCTION RTR PIPING SYSTEM

1.0 SCOPE & PURPOSE

This Procedure shall apply when Installing Reinforced Thermosetting Resin Pipe (RTR Pipes) for the
project BI-21-00044.

The purpose of this work instruction is to define the RTR Piping System and the responsibilities of
various personnel involved, in order to meet Saudi Aramco specification requirements.

2.0 REFERENCE

SAES-L-105 - Piping Material Specification

SAES-S-020 - Industrial Drainage & Sewers

SAES-B-017 - Firewater System Design

01-SAMSS-029 - RTR (Fiber glass) sewer pipe & fittings for gravity flow

01-SAMSS-034 - RTR (Fiberglass Pressure and Fittings)

SAES-S-010 - Sanitary Sewers

SAES-S-070 - Installation of Utility Piping

SATIP-L-350-05 - Fire Water Distribution Piping Installation

SATIP-S-070-03 - Thermoplastic and RTR Piping

SATIP-S-070-01 - Earthwork – Excavation and Backfilling for Underground Utilities

SATIP-L-350-07 - Cement Line Pipe Installation

Construction Scope of Work

3.0 DEFINITIONS & ACRONYMS

SATIP - Saudi Aramco Typical Inspection Plan

SAIC - Saudi Aramco Inspection Checklist

SATR - Saudi Aramco Test Report

SAES - Saudi Aramco Engineering Standard

SAEP - Saudi Aramco Engineering Procedure

G.I. - General Instruction

ITP - Inspection & Test Plan

RTR - Reinforced Thermosetting Resin

MSC - Metals Services Company

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WORK INSTRUCTION RTR PIPING SYSTEM

4.0 RESPONSIBILITIES

4.1 Project Manager

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

4.2 Construction Manager

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

4.3 Superintendent/Supervisor

Ensure compliance by all craftsmen to the requirement of this procedure, relevant

Specifications and QC Inspection requirements confirm the availability of all materials, tools,
equipment and personnel necessary to complete RTR piping systems in a timely manner.

4.4 Safety Officer

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

4.5 Material Controller / Storeman

Carries out all requirements of this procedure, Manufacturers recommendation, Quality

Control Plan and relevant Customer Specifications & Standards. Liaise with QC Inspector.

4.6 QC Inspector

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

5.0 PROCEDURE

5.1 Material Control

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

5.1.2 RTR pipes shall be stored out of direct sunlight in stacks or racks as follows:

a) If pipes are stacked on each other, the stack height shall not exceed 1.5m (5 ft).
Adequate side support shall be provided to prevent slipping or rolling.

b) If pipe is stored on racks or bearing boars, the supports shall be at least 75mm
(3 in) wide. Supports shall be spaced on 3m (10 ft) centers maximum with the
first supports 1.5m, (5ft.) from the end of the pipe. The stack height shall not
exceed 1.5m (5ft.).

c) All supporting surfaces shall be free of sharp objects.

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WORK INSTRUCTION RTR PIPING SYSTEM

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

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

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

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

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

5.2 RTR Pipe Assembly

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

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

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

5.2.4 Field-fabricated mitered fittings shall be used.

5.3 Installation

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

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

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

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

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

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

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WORK INSTRUCTION RTR PIPING SYSTEM

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

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

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

5.3.10 Before installation the inside of all pipes and fittings shall be examined to ensure that
they are free of dirt and other obstructions. Any dirt or foreign matter shall be blown
out with air of flushed out with water prior to installation.

5.3.11 Ensure that pipes are adequately protected from damage due to impact shocks and
free fall during handling and lowering.

5.3.12 Materials, adhesive, tool availability and compatibility shall be verified in accordance
with the requirements of the RTR pipe manufacturer.

5.3.13 Assembly and installation of RTR pipes shall be in strict accordance with the
manufacturer’s written instruction.

5.3.14 Unrestrained gasket joint piping must be assembled in the trench.

5.3.15 Ensure that the laying of pipe in finished trenches is commenced at the lowest point,
with the spigot ends pointing in the direction of flow.

5.3.16 Pipe shall be laid accurately to the line grade as designated on the job plans.

5.3.17 Night caps and/or end protective caps shall be provided on the end lines of pipe
spans that have been laid at the trench at the end day of work.

5.3.18 Backfilling shall be in accordance with Project Standard and Specifications.

5.3.19 Fire Water (FW) RTR Pipe on trench installation shall be in accordance to
SAES-S-070, Para. 9.7.3

5.4 Qualification of Installers of RTR Piping

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

5.5 Hydrostatic Testing

5.5.1 Unless prevailing conditions or regulations require full backfilling of the piping prior to
the hydrostatic test, underground piping shall be partially backfilled with all joints
exposed during the hydrostatic test.

The exposed joints shall be shaded from direct sunlight, and the hydrostatic test
shall be performed so that the temperature of the thermoplastic piping material or
the temperature of the test does not exceed 40 deg C (104 deg F) during the test
period.

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WORK INSTRUCTION RTR PIPING SYSTEM

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

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

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

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

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

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

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

5.5.9 Leaking pipe, joints and fittings shall be replaced.

5.5.10 The hydrostatic shall be repeated after the repair of any defects until the system is
proved satisfactory.

5.5.11 The piping shall be satisfactory if there is no evidence of leakage or pressure loss
after the specified test period.

5.5.12 Hydrostatic Test of Fire Water Line the pressure at 200 psig and 4 hours duration on
exposed joint and shall be in accordance to SAES-B-017 Para.12.6b and 12.6c.

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WORK INSTRUCTION RTR PIPING SYSTEM

6.0 SUPPORTING DOCUMENTS

FILE
RECORDS FORM No. REMARKS
LOCATION
Inspection of Fire Water Distribution Piping
SAIC-L-2055 DCC (Site)
Lay-out (Buried & Aboveground )

Installation of Fire Water Isolation Valve SAIC-L-2056 DCC (Site)

Fire Hydrants, Monitors, Hose Reel and Riser

SAIC-L-2057 DCC (Site)
Installation Inspection

Flange Joint Inspection – Gasket Verification

SAIC-L-2014 DCC (Site)
and Bolt Tightening

Flange Joint Tightening Inspection Report SATR-L-2001 DCC (Site)

Assembly and Laying of RTR Piping SAIC-S-4058 DCC (Site)

Excavation, Placement and Compaction on

SAIC-S-1005 DCC (Site)
Non-Subkha Areas

Compaction Testing SAIC-A-1005 DCC (Site)

Final Inspection SAIC-S-1007 DCC (Site)

Inspect Joint Preparation of Cement Lined

SAIC-L-2075 DCC (Site)
Piping Fabrication or Installation

Inspection of Repair to Cement Lining SAIC-L-2076 DCC (Site)

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