Released: Company Document No: Document Class

Company Document No : RLE-2000-CPR-56123
Document Class : 1
Area : RAS LAFFAN EXPORT COMPRESSION
Discipline : CIVIL / EARTHWORK
Document Type : PROCEDURE
Contract Number : DC-PRM-581
Document Title : Method Statement for GRP / GRE Piping

Installation & Jointing Work
RELEASED
© This document is the property of Dolphin Energy Limited. No part of this document may be reproduced or transmitted in any form or by any means, or used for
any purpose other than that which it is specifically furnished without the written consent of Dolphin Energy Ltd.
File Name:RLE-2000-CPR-56123_C04 Page 1 of 32

EXPORT GAS COMPRESSION FACILITIES UPGRADE PROJECT Company Doc. No.: RLE-2000-CPR-56123
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Document Title : Method Statement for GRP & GRE Piping Installation & Jointing Works
REVISION HISTORY
REV DATE DESCRIPTION
A01 06/04/2014 Issued for Approval
Company Comments Incorporated
Company Comments Incorporated
C04 16/10/2014 Approved for Construction
Note:
A revision line in the right hand margin denotes revisions.
File Name: RLE-2000-CPR-56123_C04 2of 32

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TABLE OF CONTENTS
1.0 PURPOSE.................................................................................................................................... 4
2.0 HEALTH, SAFETY & ENVIRONMENT........................................................................................4
3.0 DEFINITIONS............................................................................................................................... 4
4.0 RESPONSIBILITIES.................................................................................................................... 5
5.0 SCOPE OF WORK....................................................................................................................... 5
6.0 REFERENCES............................................................................................................................. 5
7.0 METHODOLOGY......................................................................................................................... 6
7.1 General Requirements..............................................................................................................6
7.2 Permit To Work......................................................................................................................... 6
7.3 Handling & Storage................................................................................................................... 6
7.3.1 Loading & Unloading...............................................................................................................................................6
7.3.2 Storage of Material.................................................................................................................................................6
7.4 Prefabrication of Spools on Site................................................................................................7
7.5 Installation of Underground Pipe System..................................................................................9
7.5.1 The Trench Construction.........................................................................................................................................9
7.5.2 Backfilling..............................................................................................................................................................10
7.5.3 Spools Laying.........................................................................................................................................................10
7.5.4 Spool Jointing........................................................................................................................................................11
7.6 Installation of Above Ground Pipe System..............................................................................18
7.7 Hydrostatic Test Procedure.....................................................................................................19
7.7.1 Fire Water System (GRE Pressure Lines)...............................................................................................................19
7.7.2 HW System (GRV Gravity Lines)............................................................................................................................22
8.0 REPAIR PROCEDURE.............................................................................................................. 22
8.1 Pipeline draining:..................................................................................................................... 22
8.2 Cutting the leaked portion (joint or pipe):.................................................................................23
8.3 Installation & Lamination of new pipe piece:............................................................................23
9.0 JOB SAFETY ANALYSIS.......................................................................................................... 24
10.0 ATTACHMENTS........................................................................................................................ 25
10.1 Appendix- 1a: Sample Formula for pressure drop acceptance................................................25
10.2 Appendix- 1b: Lamination Recipe for different size of GRP/GRE pipe....................................28
10.3 Appendix- 1c: Torque Value....................................................................................................31

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1.0 PURPOSE
The purpose of this method statement is to describe the requirements, sequence, arrangement,
and method needed to be followed for GRP/GRE piping installation & jointing works, as per
project requirement for the Export Gas Compression Facilities Upgrade Project for Dolphin
Energy Ltd, Ras Laffan city.
2.0 HEALTH, SAFETY & ENVIRONMENT
1. PTW Authorization, approved method statement & other relevant documents must be
obtained prior to actual commencement of the work and available on site at all times.
2. Ensure that all staff and workmen assigned to carry out the task have attended and
successfully completed the mandatory Safety induction and other relevant trainings by
CONRACTOR.
3. Work site supervisor will be available on site at all times.
4. Recorded Tool Box Talk shall be carried out by safety engineer / discipline supervisor /
foreman emphasizing the hazards that may be encountered & the hierarchy of control
measures to be undertaken prior to commencing the task.
5. All the safety requirements stipulated in thePTW shall be strictly followed inside construction
area.
6. Appropriate and correct Personal Protection Equipment’s shall be provided and worn at all
the times.
7. All lifting equipment must be in good condition and shall have relevant valid TPI certificates.
All operators shall have relevant valid TPI certificates.
8. Dedicated Fire Watcher & Safety watcher will be engaged at each naked flame permit
works.
9. Dry powder fire extinguisher shall be available at site during the work
10. The completed scaffold shall be inspected and “Green Tagged” before use.
11. Method statement shall be approved by COMPANY.
12. Site Supervisor should closely monitor activity and recommend mitigation control measures,
if unsafe act and condition have been noted during and throughout the course of work.
13. All access / exit point to work areas will be ensured free from any obstacles, materials and
equipment.
14. All work will be stopped in case of any incident and reported to the GRPL Site
representative, Contractor’s HSE manager, Project Manager and Construction Manager and
COMPANY representative immediately. Work shall proceed only after investigation &
corrective actions are in place and approved by COMPANY to proceed further.
3.0 DEFINITIONS
COMPANY : Dolphin Energy Limited/DEL

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CONTRACTOR : Larsen & Toubro Limited/L&T

SIL : Simplex Infrastructure Limited (Sub-contractor)
GRPL : Gulf Reinforced Plastic LLC (Subcontractor)
JSA : Job Safety Analysis
HSE : Health Safety & Environmental
PPE : Personal Protection Equipment
4.0 RESPONSIBILITIES
SIL and GRPL are responsible for the installation of GRP/GRE spools as per the scope detailed
in the contract agreement between Client & GRP, includes offloading, storing, laying, aligning,
jointing the spools & installed lines.
SIL and GRPL will arrange all the resources necessary to execute the works following the
standard procedures of GRPL, Pipe manufacturer, Client specs. GRPL will report to Client on
daily basis the installation progress and the quality control records and of any technical problem.
GRPL Site representative shall be responsible for implementation of this Method statement
during erection & jointing works.
GRPL QA/QC inspector/Representative shall ensure and monitor the implementation of this
Method statement during installation works.
Project Manager shall report to Branch Head of Subcontractor and for single point coordination
with Contractor’s Civil Works representative. Shall be responsible for overall control of project
and shall coordinate with all discipline heads viz. quality and safety.
Site Engineers shall report to Project Manager and shall be responsible for Work Activities
mentioned in this Method statement.
Safety/Environment Officer shall report to Safety Manager and coordinated with Project
manager and safety department heads of main contractor as well as client. Shall also be
responsible for monitoring safety performance and necessary initiation of corrective action
through line management for all technician /labors.
QA/QC Engineer Will monitor and guarantee Quality Confirmation of the Works.
Report to Quality Manager and coordinate / consult with Project Manager.
5.0 SCOPE OF WORK
This Method Statement covers the minimum requirement for the installation of GRE/GRV/GRP
underground and above ground piping work at projects.for the Export Gas Compression
Facilities Upgrade Project for Dolphin Energy Ltd, Ras Laffan city.
6.0 REFERENCES
Wavistrong Installation Manual Rev 02
Fiberstrong Installation Guide for U/G Piping Systems, Rev 1
Fiberstrong A/G Piping System Selection & Installation Guide, Rev 1
ISO 14692 – Part 4, First edition 15-12-2002

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Site QA/QC Procedures & Forms GRP/PJ/QM-01, Rev 6
GS EP PVV 178 – Design & Erection of GRP Piping Systems in DEL

7.0 METHODOLOGY
7.1 General Requirements
 The Jointing technician qualification certificates from Pipe vendor (Future Pipe Industries)
shall be submitted for COMPANY Approval prior to execute the job. (Appendix 2)
 ITP shall be submitted for review and approval of the COMPANY before starting the job.
 Certified FPI supervisor will be available at site.
7.2 Permit To Work
 PTW holder shall be qualified well in advance before start of piping activity in
Construction site area.
 The assigned authorized personnel shall raise PTW and obtain necessary clearance as
required for working in Plant area refer to Permit to work Procedure QQH-GEN-0000-
OSP-00001.
7.3 Handling & Storage

7.3.1 Loading & Unloading
The spools will be delivered to site by SIL. GRPL will offload the spools and place them
in storage area provided by SIL.
In addition to delivery notes, GRPL will use the form “Product Information” to keep
record of delivered spools.
Chains, steel cables, or clamps will not be used during lifting for loading/unloading.
Nylon or canvas hoisting belts with a minimum width of 10 cm shall be used. Standard
pipe lengths shall be picked up at two supporting points. Hoisting belts shall always be
placed around the widest part. Flatbed trailer shall be used during shifting of pipes from
lay down area to work site.
QA/QC Forms
 Delivery notes
 Form “Product Information” to keep record of delivered spools.(ITP approved
checklist)
 Form Material Handling (ITP approved checklist)
7.3.2 Storage of Material
In order to avoid damage to the stocked pipes, fittings and bends the following rules
must be observed:
 Do not lay the pipes directly on the ground, onto rails or concrete floors. Provide a
flat surface, i.e. compacted sand.
 Suitable supports shall be used for example wooden planks, measuring 10X5 cm,

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the distance between supports shall not be more than 3 m. To avoid damage to pipe
ends, stocking shall be undertaken with care. (See Fig 1).
 Pipe stacks shall have side supports or blocks to prevent rolling or slipping of the
stack.
 Unprotected flange-faces shall never be placed directly on the ground or on concrete

floors.
 Resin and catalyst/hardener/adhesive shall be stored in original packing with caps

inside containers/shade at temperature less than 30oc.
 Catalyst and accelerators if any shall not be stored close to each other.
 GRPL will complete the checklist “Storage Condition” on a daily basis to conform to
proper storage.
Figure 1
QA/QC Forms
 Checklist “Storage Condition PJ/2P-1.1” on a daily basis to conform to proper stora.
7.4 Prefabrication of Spools on Site
If required, spools can be fabricated at site. Spools are generally fabricated using fittings &
pipe supplied by pipe manufacturer.
Spool shall be fabricated as per the dimensions mentioned in approved for construction
isometric drawings. Preferably, shop floor drawings for spools should be prepared for
fabrication. If shown on isometric drawings, the fabrication shall include “cut-to-fit” length on
fabricated pieces to allow for the setting up of pipe work accurately on site between the fixed
points. The “cut-to-fit” dimension shall be 150mm of pipe additional to the length shown on
the piping drawings. For hook-up spools, the “cut-to-fit” dimension shall be a minimum of
250mm in each global direction. “Cut-to-fit” length shall be Left Square and plain. Wherever
possible, actual field dimensions shall be verified with drawings before fabrication. Fixing of
the flange to the spool shall be avoided in situations where field joint is not available to
eliminate the stress on the flange while torquing of the flanged connection.
All pipes shall be carefully inspected for damage before fabrication. The conformity of each
pipe or fitting shall be verified by checking individual marking (Labeling from Pipe vendor).
Piping and fitting unmarked (not labeled) shall be scrapped. Joints shall be done according to
the Pipe manufacturer procedure and as mentioned in this MS under section 7.5.4.

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For spools with lamination joints, all the joints can be fit-layered and laminated internally
before starting the structural lamination. This way, dimension of the finished spool can be
verified and also can speed up the jointing process, as more than one joint can be started
simultaneously. Otherwise second joint can be started only after curing of previously
completed joint. But fit layer on the joint shall be cured before proceeding with the fit layer on
the next joint.
Internal Lamination is not applicable upto 600 mm.
For spools with adhesive joint, the joint shall be properly cured before proceeding to the next
joint. Dimensional tolerances of finished spools shall conform to ISO 14692 as shown in the
table 1.
The dimension numbers are shown in Fig.2. The acceptable tolerances for misalignment of
the flanges are given in Table 2. The gap in the bolt hole owing to its larger size than bolt
sizes should be taken into account when assessing the values in Table 1 & Table 2.
Table 1 – Max. Dimensional Tolerances

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Fig 2 – Dimension numbers given in Table 1

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Table 2 –Tolerances for flange misalignment
QA/QC Forms
 Spool Fabrication Report -Form (ITP approved checklist)
 Joint Record Forms (ITP approved checklist)
7.5 Installation of Underground Pipe System
Special attention needs to be given to the bedding, side filling and backfilling of the trench.
This provides the necessary support to the pipe. It also prevents settlement and possible
damage by erosion and / or traffic. Resistance to horizontal movement of the pipe depends
on the soil type, its density and moisture content. The greater the soil resistance, the less the
pipe will deform or move, when fully buried and compacted.
7.5.1 The Trench Construction
The civil contractor will open the trenches as per the civil works drawings. The trench
dimensions should comply with the requirements specified in pipe manufacturer’s
installation manual & project specification. As per project specification, the trench width
shall be comprised between pipe OD + 0.3 m and Pipe OD + 0.9 m.
The pipe trench shall be smooth, regular and free from stones or any other hard objects,

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which may damage the pipe or cause stress concentrations.
The surface of the bedding layer should be at the same elevation as the pipe invert level.
The trench should be over-excavated under the joints to allow for space required for the
jointing activity, as well as inspection for monitoring leaks during hydro test.
Protective warning tapes shall be installed for protective grillage purpose.
The civil contractor shall submit the compaction test results for the trench bedding along
with trench handover note, proving that desired compaction has been reached. Upon
receiving trench hand over note, GRPL will inspect the opened trenches and will issue a
“Trench Acceptance Report”. If the trench is not accepted by GRPL, civil contractor to
take necessary actions. Pipe laying will be started only after the trench is accepted by
GRPL.
QA/QC Forms
 Trench Acceptance Report (ITP approved checklist)
7.5.2 Backfilling
After the spools are jointed and inspected and if the “Line Co-Ordinate and Elevation
Report” report is approved, only then will the civil contractor start the backfilling. The
lines will first be released for partial backfilling. The spools will be covered with the
compacted backfill soil up to minimum one diameter above the crown level with a
minimum of 300mm and a maximum of 1m. At this stage, the joints will be kept exposed
to allow a proper inspection during the hydro test. It is important that partial backfilling
follows closely the pipe installation as covered pipes will not expand due to thermal
variations.
In the same form, the civil contractor will be also given the approval to pour concrete
around the installed pipes as specified in the approved isometrics, e.g. at wall insert in
the valve/discharge pits.
After the successful hydro test, GRPL will release the tested lines for complete backfill
up to the grade level. The same release note used for the partial backfill release will be
used at this stage.
Backfilling shall be carried out in accordance with the procedures mentioned in pipe
manufacturer’s installation manual and those mentioned in the procedure “Requirements
from Civil Contractor”.
7.5.3 Spools Laying
The spools will be laid by GRPL according to the coordinates and the elevations
specified in the approved isometrics, or otherwise as directed by Client.
All pipes shall be carefully inspected for damage before installation. Pipes with laminated
joints can be double-jointed beside the trench in order to reduce the number of bell holes
in the trench bedding & installation time; and next day, lowered into the trench. This
must be done with reasonable care in order to prevent overstressing of the pipe. Do not
move the joint during curing. As the maximum size of pipe to be handled is 600 mm dia
and maximum length of double pipe shall be 24 m, the weight to be handled shall not

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exceed 2 ton. A 30 ton Crane shall be utilized fr erection of piping spools into the
underground trenches with permissible boom range of 12 to 15 meter from the trench.
Doubled pipe shall be installed with the aid of 12 meter spreader beam to secure the
pipe & joint due to angular deflection during handling of pipe. In case of doubling pipes
spreader beam (with TPC) will be used.
Following are the methods, which shall be used for the installation and adjusting of pipe
systems in the field:
 Adhesive Bonded Joint

 Lamination Joint
 Flanged Joint.
7.5.4 Spool Jointing
7.5.4.1 Adhesive Bonded Joints
Before adhesive bonding, all safety precautions shall be checked. Ensuring that all
necessary tools and materials are available.
Cutting
The pipe section to be cut shall be marked using a marker pen and a pipe fitter’s
wrap-a-round guide. Ensure that the cut end is completely square as the reliability
of the joint depends on it. Pipe up to 100mm dia should be square to within 1.5mm
and for the pipes above 100mm dia, squareness should be within 3.0mm. Correct
the squareness of the pipe end using grinding disc. The cutting of glass fiber
reinforced epoxy pipes can be done by means of a (abrasive) cutting disc (diagrit
or carborundum).
Machining
After the pipe has been cut to the exact length, the end will have to be ground to
the right diameter to ensure a proper joint. The surface shall be cleaned with a
clean cloth. If the surface has been in contact with oil or grease, it shall be cleaned
with a clean cloth soaked in solvent such as pure acetone. Do not use paint
thinners or petrol or alcohol for cleaning. After drying, machining can start. Pipe
end can be machined as follows:
The pipe shall be firmly supported and fixed. When holding the pipe in a vise, use
rubber padding or similar to protect the pipe from damage.
Mark the shaving length (provided by pipe manufacturer) from pipe end and scribe
using a pipe fitter’s wrap-around.
For Tapered joints, shaver machine that can shave at the specified angle (1.750
upto 100mm dia and 2.50 for dia 150mm and above) should be used. In case of
the shaver machines that can be set at different angles, correct angle should be
set before start shaving.
Expanding mandrel will be inserted into the pipe. Turn the spindle and keep the
expanding mandrel in position until it has been tightened against the inside of the
pipe.
After connecting and turning on the power unit, the post should rotate in a
clockwise direction. Care shall be taken when shaving the first layer, because the
pipe wall may not be equally thick on all sides.

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As soon as the spigot end has been machined to the required length and diameter
as specified, power unit to be removed. The spindle shall be turned anti-clockwise
and it should be pressed forward to loosen the expanding mandrel and then
removed.
The tolerance on the spigot diameter shall be regarded. Assembly of the joint shall
be done within 2 hours of machining. Otherwise refresh the machined surface
using grinding disc.
Preparation for Bonding:
Measure back from the edge of the spigot the required insertion depth plus 50 mm
and scribe a line. After the joint assembly, scribe on the pipe should be 50 mm
from end of the bell.
Mark the pipe and fitting for alignment of elbows, flanges etc.
Sand the shaved spigot end using emery paper or disc to have a dull, fresh finish,
not a polished look. Remove the dust from the surface using a brush or blower.
If the surface has been in contact with oil or grease, it shall be cleaned with a clean
cloth soaked in solvent such as pure acetone and sand the surface.
Sand the bell end using emery cup of grit 40-60mm. Remove the dust from the
surface using a brush or blower. For small dia pipes where use of emery cup is
difficult to use (like 25, 40, 50mm dia), sanding of bell can be done with a sand
paper.
Do not touch the sanded surface after sanding and cleaning.
For tapered joints or normal cement joints for which hand pullers will be used to
pull the joints (dia above 200 mm), install the pipe clamp or span set on both
components keeping sufficient space for the hand puller when pulling the joints
together.
Bonding of the Joints
a) Adhesive Kit:
The adhesive kit consists of two components: resin and hardener. The
adhesive kits have to be stored at temperature below 30°C. The two
components have to be mixed between 20°C and 55°C. Below 15°C the
components will not mix well and the adhesive cannot easily be spread on
spigot and socket end. The mixture will cure too fast above 40°C and it is
important that the adhesive cement mix should be spread on the pipe as fast
as possible. The setting times after mixing are given in Table 3 below.
Table 3
Temperature of
20°C 25°C 30°C 35°C 40-55°C
adhesive
Setting Time 30 min. 25 min. 20 min. 15 min. 10 min.
Or otherwise as indicated at detailed instructions supplied with Adhesives.

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Note: The application & the pot life of adhesive kit at temperature above
40oC up to 55oC are acceptable if the joint is to be done within 10 minutes.
If the temperature is less than 20°C, warm the cement lightly.
Temperatures and Relative Humidity Requirements:
The bonded assemblies may be performed only if the temperature of the

pieces to be assembled is 5°C above the dew point and if the relative
humidity is lower than 85%.
b) Mixing:
Hardener from the small container is to be added to the resin in the large
container and mixes with the spatula for at least 3 minutes until the mixture
has a uniform color. Adhesive is to be applied on the prepared surfaces
immediately after mixing. Setting time shall be observed (see table above).
Adhesive, which has started to cure or turned more tacky, shall not be used
as it will lead to an imperfect joint.
c) Applying the adhesive:

A thin and uniform layer of adhesive of approximately 0.5-0.8 mm thickness is
to be applied to the inner surface of the socket with the supplied stick or a
rubber spatula. Too much adhesive in the socket will result in a flow
resistance. A uniform and thicker layer of approximately 0.8-1 mm thickness
has to be applied to the outer surface of the spigot and a thin layer to the cut
end of the pipe. If the surface temperature of the pipe is less than 20°C,
warm the surface using heating blanket.
d) Assembly of the joint:

Insert the spigot into the socket end until the joint is firmly fixed together and
there is 50mm gap between the bell end and the mark; attention has to be
given to the marks and position. Rubber hammer may be used to tap directly
on fittings for proper seating.
For diameters above 200 mm, hand pullers with span set belts may be used
to pull the joints together.
For tapered cement joints, the hand pullers shall be used to pull the joints.
Hook the 2 hand pullers (one on each side) to the clamp or span set belt and
start pulling the joint in a smooth movement until the joint is pushed home.
Keep a wooden spacer underneath the hand puller to protect the pipe and to
provide space for placing the heating blanket. For tapered joints, hand pullers
shall not be removed until the adhesive has fully set.
The excessive adhesive should be removed from the surface with the spatula
(and if possible from the inside of the joint). The curing of the adhesive should
not be disturbed by moving or vibrating the joint.
The room between the socket and machined spigot shall be filled with
adhesive (finishing layer).
For flanges, check rotational alignment of bolt holes and squareness of flange
faces. The tolerances are shown in Table 1 & Table 2.
If misaligned, pull joint apart, remove adhesive from pipe stop area, reapply
the adhesive and rejoin before adhesive start to set. Avoid having to rotate

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the part while assembly.
e) Curing of the joint:

Proper curing method and curing time depends on type of adhesive used,
temperature of the pipe and conditions of the service.
If additional heating is required to cure the joint, heating blankets are used.
Select the required size heating blanket and place thermostat end of the
blanket against the assembled joint with the thermostat side facing out from
the joint. Wrap the reminder of the blanket around the joint so that any
overlap will cover the thermostat. Tie the blanket in place any nonconductive
tie. Connect the power supply and cure the joint for the required duration. The
curing time starts after surface of the pipe has reached the required
temperature underneath the blanket. The curing time is estimated to be 1
hour at 125o C.
The flanged joints and laterals, because of their configuration, are difficult to
cure from outside using heating blanket. For such joints, roll up the heating
blanket and place it inside of the pipe at the machined end. Ensure that
blanket is pressed against the pipe wall. This can be done by filling the space
inside the blanket with heat resistant material.
Note: Do not move the joint during setting of the adhesive. This can result in
failure of the joint.
QA/QC Forms
 Cement Joint Inspection Record-Form (ITP approved checklist)
Tools For Cement joint
For cement joints the following is needed.
 Measuring tape, pipe fitter’s wrap-around, PI Tape, marker pen.

 Cleaning rags, brushes, Cleaning liquid like acetone or methylene chloride
 Angle grinder
 Diagrit or carborundum cutting disc + sanding disc (grit 24) + flexible support
disc
 Pencil Grinder + flapper sander or drill machine + emery cup (grit 40-60) +
holder
 Rubber Hammer.
 Shaver Machine + Mandrel + Power Drive
 Pipe clamp or spanset belt, hand puller, wooden spacers
 Gloves, dust masks, safety glasses.
 Heating blanket, Thermometer, Temperature regulator.
 Shade
 Pipe stand
 Generator
7.5.4.2 Lamination Joint

Before starting a lamination joint, all safety precautions will need to be checked.
Ensure that all necessary tools and materials are available. Lamination recipe shall
be present on site during lamination jointing.
Following notes should be taken care of:

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 Lamination should be avoided in foggy conditions.
 The length of exposed pipe should be kept minimum especially during

summer to avoid effect of expansion/contraction of the pipe on the new
lamination joints. This can be done either partially backfilling the jointed
section or by covering at least 2 lengths of pipe with tarpaulins.
 In case of long lines, it is preferable to do erection and jointing in sections on

either side of the manhole spool; manhole spool erected and jointed last to
connect the jointed sections.
Winding Method:Cutting and Sanding

Mark off the pipes to be joined using a pipe fitter’s sleeve and felt tipped pen. Cut
the pipe (sections) to the right length, with a straight cut perpendicular to the pipe
axis. The pipe can be cut using a diagrit, carborundum-slitting disc or with a
diamond edged disc. Use a sander (Angle grinder) to remove the topcoat of the
pipes when cut to the right length, in order to give a clean and rough surface for
adhesion. Clean the sanded part with a clean cloth or brush. The pipe sections
must now be clean and free of dust. In case of oily contamination, wash with
methylene or acetone and re-grind.
Mixing :Epoxy Resin:

The hardener must be added to the container with the resin and carefully mixed.
The resin and hardener shall be mixed as per the quantities mentioned in the
recipe to maintain the right mixing ratio or as the ration given by resin/hardener
manufacturer.
The resin in the mixing container shall be weighed using hanging weighing scale
before adding hardener. Hardener then is weighed to the required quantity as per
mixing ratio and carefully mixed using a mechanical mixer.
Pre-accelerated Polyster/Vinylester Resins

Pre-accelerated resins already been mixed with Accelerators like Cobalt & DMA by
the supplier according to the local atmospheric conditions. Only the catalyst is
required to be added to resin. The resin and catalyst shall be mixed as per the
quantities mentioned in the recipe to maintain the right mixing ratio. The catalyst
must be added to the container with the pre-accelerated resin and carefully mixed.
Quantity of resin to be mixed at a time shall be judged by the crew leader (normally
about 5-6kg) depending on the total resin quantity for the lamination, crew strength,
and environmental conditions. The resin in the mixing container shall be weighed
using hanging weighing scale before adding catalyst. Catalyst of required quantity
shall be added using graduated dispenser.
Raw Polyster/Vinylester Resins:

For raw resins, accelerators & catalyst shall be added. Mixing ratio depends on the
required gel time, atmospheric conditions and concentration levels of accelerator &
hardener. Gel time is to be assessed judiciously based on the time required to
complete the joint, lamination thickness, crew strength but limiting the mix ratios
within the range specified by the resin/pipe manufacturer.
After transferring the required quantity of resin to the container, weight of the resin
shall be determined using weighing scale. The accelerators Cobalt & DMA will then
be added one by one using graduated dispenser according to the mixing ratio
provided by the resin/pipe manufacturer or as decided by reactivity test. Carefully
mix using mechanical mixer. Finally catalyst shall be added using dispenser

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according to mix ratio and mixed carefully.
Approximate mixing ratios for different gel times are given below with following
accelerators and catalyst. Data given by resin/pipe manufacturer shall be given
priority over this table.
MEKP: Peroxide Catalyst

Co: Accelarator Cobalt octoate 6%
DEAA: Accelarator
TBC: Inhibitor (Ter-Butyl-Catechol)

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Mix Ratio for Raw Vinyl Ester Resin
Mix Ratio for Raw Polyster Resin
Important Note: Do not mix accelerator and catalyst directly as Explosion

may occur.
Reactivity test:
Reactivity test will be done on site and is under GRPL QC inspector responsibility.
This test shall be conducted to determine and also to verify resin gelling time. The
test shall be conducted for every new batch of resin, when there is a significant
change in ambient conditions or whenever something unusual is noticed in the
resin gelling.
Mix about 100 gm of resin with additives for the test temperature. Note the gel time
using a thermometer with probe immersed in the resin. Gel time is the time
required to reach a temperature 10oC higher that the temperature at start of the
test. If gelled time is very different from the table or provided by supplier, or if the
resin does not react at all, then the batch shall be rejected. Make sure which
component (resin or catalyst or accelerator) is inactive by repeating the test with
different batches before rejecting.
Fit Layer
The functions of the fit layer are, firstly to ensure proper positioning and secondly,

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to create a seal (see Fig. 3).

Measure fit layer bond length (mentioned in recipe) from the end of each pipe.
Grind the above area to remove the surface layer of the pipe and remove the dust
using clean dry cloth or brush.
Fill the gap between the two pipes with cab-o-seal putty.
Apply woven roving in layers mentioned in the recipe with 50% overlap between
each two consecutive windings. Impregnate the layers with the mixed resin.
Fit layer shall be completed in single stage. i.e partial or section by section fit layer
is not allowed.
External Lamination (Main Laminate)
Measure the bond length (mentioned in recipe) on each pipe from the middle of the
fit layer.
Grind the above area to remove the surface layer of the pipe and remove the dust
using clean dry cloth or brush. The work must continue within an hour, otherwise
the grinded surface shall be refreshed using grinder.
Apply woven roving in layers mentioned in the recipe with 50% overlap between
each two consecutive windings. Impregnate the layers with the mixed resin.
After application of required layers of roving, wind 2 layers of top tape around the
laminate to extract the excess quantity of resin and to provide smooth surface.
Fig. 3
7.5.4.3 Flanged Joint
The fiberglass flanges must always be installed tension free; therefore flanges
must be accurately aligned. If possible, flanges should be jointed to pipe only after
bolting the flange to the required torque value.
Before assembling flanges, inside surface of the flange will be cleaned and
checked for any defects or irregularities on the flange’s gasket face.
Steel blind flanges to be used during the hydro test and/or if connected to the
fiberglass flanges permanently should have either thickness specified by Pipe

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manufacturer or alternatively should have adequate steel reinforcement bracing for

blind flanges of lower plate thickness.
Gasket shall be checked for any defects and will be cleaned on both sides.
Permanent gaskets used should be as per the project specification or as
recommended by pipe manufacturer.
Gasket will then be fixed in position using masking tape.
Make sure that the mating flange is properly supported to avoid load being
transmitted to the fiberglass flange.
Insert flange bolts, washers and apply nut until it is hand tight.
Number each bolt starting at the top in a clock-wise direction as per the torque
sequence.
Once all the bolts are hand tight, bolts will then be tightened in sequence using a
calibrated torque wrench up to the 30% of the max. torque value provided for that
particular gasket, diameter and pressure rating (Torque values to be provided by
Pipe manufacturer). In case of leak, bolts will be again tightened in sequence using
the torque wrench up to the 60% of the max. torque value
Tightening will be done as per the torque sequence provided by Pipe

manufacturer.
After all bolts have been tightened to recommended torque, recheck the torque on
each bolt in the same torque sequence.
QA/QC Forms
 Flange Joint Inspection Record-Form (ITP approved checklist).
Tools for Flanged joint
For flanged joints the following is needed.
 Spirit level, Square angle, Marker pen, Measuring tape.

 Cleaning rags, Masking Tape
 Combination spanner of required size.
 Calibrated Torque Wrench of required capacity with wrench sockets.
 PPE.
7.6 Installation of Above Ground Pipe System
To ensure the optimum performance, the pipe system shall be installed as per the relevant
isometric drawing and piping support design provided by pipe manufacturer.
All flanged connections shall be made in accordance with pipe manufacturer’s procedure, as
mentioned above, particular attention shall be given to Flange alignment and torque settings.
Following points has to be taken care during erection:

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 Flanges connecting to the fixed points/equipments shall be torqued with mating flange
before doing the last joint on that spool.
 If any equipment is to be installed between two GRP flanges, equipment shall be torqued
to the flange that is jointed to the line. Other flange shall be jointed to the line only after
torquing with the equipment. This will avoid any misalignment between the flange
connections. Equipment shall be supported individually.
 Pipe shall be centered with support base plate.
 Pipes shall be properly leveled and aligned.
 Pipes shall not touch with any other structures or pipes.
 Joints should be avoided at the support clamp locations. Joints should not be touching
with clamp plate as this will prevent movement of the pipe unless otherwise support does
not permit axial movement of the pipe.
 Support clamps shall not have direct contact with pipe, rubber padding shall be provided
in between.
 Supports shall be installed properly to allow functioning as required by the pipe

manufacturer or system designer as per the stress analysis.
 Collars shall be provided on the pipe at supports where axial movement of pipe is to be
arrested. On vertical lines, collar shall be provided at least on the topside of the clamp to
resist downward movement of the pipe.
 Grouting of the supports shall be done only after completing erection of supports.
7.7 Hydrostatic Test Procedure
7.7.1 Fire Water System (GRE Pressure Lines)
7.7.1.1 Pretesting Conditions
It is deemed that the line will have been kept clean during storage and construction
by keeping the open ends capped, that the hydro test package checklist points
have been verified and that the line is released for hydro test and all safety
precautions are taken.It is important that the backfill and compaction of the line is
done according to the installation procedures, as this will prevent the line from
moving during pressurizing as well as providing protection against impacts, shade
etc. Joints shall not be backfilled.
A taped off area will be delimited around the test pump, the diameter of this area
will be 1.5 times the length of the test pressure hose between pump and blind
flange; where only designated personnel will have access. Repetition of pressure
test for same spools under same test condition (1.5 times of design pressure) is
maximum 03 times.
7.7.1.2 Hydrotest Preparation
 Any required temporary piping facilities; make up dummy spools will be

installed.

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 The main blind flange will be fitted inter alia, with a manifold.
 2 nos. calibrated pressure gauge ranging from 0 to 1.5-2 times test pressure
will be installed on the line. They must have valid calibration certificate.
 The pressure hose will be connected to the blind flange manifold through a
NPT connector. Calibrated Relief valve with a set pressure 1.1 times the test
pressure needs to be kept connected to the hydro test pipeline.
 Venting facilities: All steel blind flanges will be provided with bleed valves,
either ½” or ¾” Dia. All high points will have a venting facility.
 The line will be filled with water through tanker trucks or pumps the previous
day to testing to allow for thermal stabilization over-night.
 The filling of sloped lines will be done from the lowest point. The filling will be
done with all vents open, vents should be closed only when clear water with no
air bubbles come through the vent. Only when all vents are closed should the
filling pump stopped.
 The pressure test pump of appropriate capacity will be started and vents
reopened to ensure any remaining air in the pipe escapes. Once closed the
pressure will be taken up to the field hydro testing pressure. Pressure reading
at the lowest point of the test section shall be considered to avoid any over
pressurizing of the line due to head difference.
7.7.1.3 Pressure Test:
Pressure test shall be conducted with following stages:
 The start time should be recorded.
 15 minute stand-by for stabilization and monitoring will be done for every 5 bar
G
 For field joints,
At test pressure i.e 1.5 times the system design pressure, the starting time will
be logged. The test pressure will be maintained for a holding period of
minimum 24 hours continuously recorded.
 For prefabricated spools (shop tested),

At test pressure i.e 1.5 times the system design pressure, the starting time will
be logged. The test pressure will be maintained for a holding period of
minimum 4 hours continuously recorded to ensure no leakage from
prefabricated spools. Hydrostatic test shall be carried out for these spools with
MAOP (Maximum Allowable Operating Pressure) during final system testing.
 For Tie-in locations,

Hydrostatic test by using 1.5 times to design pressure will not be possible for
fire water line tie-in points. All such joints shall be treated as golden joints and a
consecrated lamination recipe (with extra reinforcement) shall be used for
these joints. Hydrostatic test shall be carried out with MAOP (Maximum

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Allowable Operating Pressure) during final system testing.
 Section wise Hydrostatic test by using 1.5 times to design pressure (with
holding time minimum 24 hour), for fire water system shall be carried out at
site. The total Fire water system shall be hydro tested with MAOP (Maximum
Allowable Operating Pressure) including tie-in locations (golden joint locations)
during final system testing.
 In the unlikely event the pressure would rise above required point, the inline
relief valve will release water until pressure drops back to its fall back pressure
(test pressure).
 Pressure drop / rise due to temperature variation shall be monitored. If

pressure drop is not within limit and no visual leakage found in line, Calculation
for allowable pressure drop due to temperature variation shall be carried out
(By pipe vendor) for test acceptance.
 If the pressure abnormally drops during the testing, indicating a leak, the
pumping should be continued until the leak is detected. The pipeline is then
emptied to carry out repair works as per Pipe manufacturer standard lamination
repair procedure as detailed in section 8.0
 Incase Pressure drop is in limit with temperature drop (variance), the test is
considered as passed.
 The pressure may then be slowly released and the line gravity drained back.
The hydro test package will be submitted one working days in advance for
Contractor’s/ Client’s review.
All the required forms and checklists as per the ITP shall be completed and signed
off by the respective representatives before the hydro test.
The Pressure test report (ITP approved checklist) shall be signed off by required
representatives of Sub Contractor & Contractor/Client after completion of hydro
test.
7.7.1.4 Safety Precautions
Required work permit for hydro testing shall be obtained from authorities prior to
water filling.
Water filling and Hydro testing will be done only during daylight conditions.
Pipeline shall be backfilled and compacted as per the procedure leaving the joints
open for inspection, as this will prevent the line from moving during pressurizing as
well as providing protection against impacts, shade etc.
Entire line will be soft barricaded with required warning signs. A taped off area will
be delimited around the test pump, the diameter of this area will be 1.5 times the
length of the test pressure hose between pump and blind flange/end cap; where
only designated personnel will have access.

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Required vehicles and testing personnel will be employed to monitor the test
section with communication equipments.
Draining pump will be kept ready to drain the line at lowest point in case of any
pipe/joint failure.
During all stages of work, utmost care will be taken to avoid damage or shock to
the lines.
 Personal movement will be kept to a minimum

 Heavy equipment circulation will be avoided.
 All Mechanical Compaction will be stopped in the vicinity
 No loose rocks or bounders will be closer than 1 (one) meter from the trench
edges
 All civil works will be stopped on the line.
7.7.2 HW System (GRV Gravity Lines)
7.7.2.1 Pretesting Conditions
It is deemed that the line will have been kept clean during storage and construction
by keeping the open ends capped, that the leak test package checklist point have
been verified and that the line is released for leak test and all safety precautions
are taken. It is important that the backfill and compaction of the line is done
according to the installation procedures, as this will prevent the line from moving
during testing as well as providing protection against impacts, shade, etc. Joints
shall be kept open for inspection. Only designated personnel will have access. The
HW pipeline to be tested normally comprises of pipeline joining HW manhole
chambers / catch basins, inline chambers and some branch connections which are
connected to various building &equipments.
7.7.2.2 Test Preparation
Drain plugs shall be installed at open ends of the pipeline and tightened to ensure
pipe end to be leak proof.
The line will be filled with water through tanker trucks. The filling of sloped lines
will be done from the lowest point, and all vents kept open until clear water flows.
The line will be filled and vented as much as possible to avoid air trap in the line..
Once stabilized the height of water will be marked on the chamber walls and the
time logged.
All joints will be checked for water tightness. If any leaks are observed the test
considered as failed. The pipeline is then emptied to carry out repair works as per
Pipe manufacturer standard lamination repair procedure. On completion of repair
and retest package approval test is repeated with same procedure as mentioned
above.
After a twenty four hours period, the height of water will be verified, if it is the same
as at the beginning, the test will be considered as passed.
The hydro test package will be submitted two working days in advance for

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Contractor/Client’s review. The required representatives will complete and sign all
paper work pertaining to the test.
8.0 REPAIR PROCEDURE
The leaked joint will be repaired with below steps:
8.1 Pipeline draining:

It is deemed that the leaks have been identified and the area has been excavated (for
underground services) prior to the commencement of the repair work. Extra care should be
strictly followed as the Line would be full of water. Temporary clamps with rubber sheets
should be placed along the leak area to detain the leak/s until such time that the line is totally
drained. This will ensure minimum water log on the working area. For Re-lamination
Procedure, the line should be free from moisture and water that would hinder the lamination
process during the whole procedure.
8.2 Cutting the leaked portion (joint or pipe):
The leaked joint is been already marked and identified during pressure test. A pipe portion of
1 m from existing pipeline is replaced with new pipe performing two nos. of butt-wrap
lamination joints. Existing pipe line is marked 0.5 meter away from leaked joint and cutting is
followed using 4 inch angle grinder having diagrit cutting disc.
8.3 Installation & Lamination of new pipe piece:

New pipe of same dimensions of cut pipe is installed and laminated with the same procedure
as mentioned in section 7.5.4.2 of this method statement. On ensuring that the lamination
joints are properly cured and approved by GRPL Quality inspector the pipeline is released for
re-testing on Client approval for the same.

EXPORT GAS COMPRESSION FACILITIES UPGRADE PROJECT Company Doc. No.: RLE-2000-CPR-
56123
EPC WORKS
Document Title : Method Statement for GRP / GRE Piping Installation & Jointing Work
9.0 JOB SAFETY ANALYSIS
S. Description of Hazard-potential incident Who or What Control measures/recovery measures Action

No Task Step Might Be Responsible
Harmed Party
1 Un loading and handling  Personnel Injury People, Assets  Only authorized trained operator shall be  Site In-Charge
of pipe by the crane  Property damage deployed for the operation.  HSE In-Charge
 Equipment failure  Operator and signalman should third party  Supervisor
 Defective slings and tackles certified
 Instability of crane  Effective supervision
 Overloading  Equipment shall be certified and complied with
local legal requirement
 Permit to system shall be followed
 Display suitable sign board
 Use adequate PPEs
2 Preparation of Pipe  Vehicle and personnel fall People, Assets  Avoid running of equipment/ vehicle close to the  Site In-Charge
bedding  Personnel injury Excavation pit.  HSE In-Charge
 Property damage  Only authorized trained operator and signalman  Supervisor
 shall be deployed for the operation
  Proper training and instruction
Joining PIPE by using  Personnel injury People, Assets  Overloading should not be allowed  Site-In-Charge
3 the crane or Chain block  Property Damage  Only trained persons shall be deployed for  P&M In-Charge
and Pulley  Equipment failure work  HSE In-Charge
 Defective slings and tackles   Supervisor
 Instability of Crane  Proper training and instructing
4 Pipe laying and fixing  Man pipe fall into trench, People, Assets  The involved equipment shall be certified and  Site In-Charge
 Trench cave- in complied with local legal requirements.  P&M
 Over turning of pipe layers  Checked all lifting, shifting and fixing equipment 
 before start the work.  In-Charge
 Personal injury  Activity shall be carry out under close  Supervisor
 Property damage supervision of experienced person.
 Suitable adequate PPE`S.

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S. Description of Hazard-potential incident Who or What Control measures/recovery measures Action

No Task Step Might Be Responsible
Harmed Party
 Briefing of tool box talks
10.0 ATTACHMENTS
10.1 Appendix- 1a: Sample Formula for pressure drop acceptance

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10.2 Appendix- 1b: Lamination Recipe for different size of GRP/GRE pipe

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10.3 Appendix- 1c: Torque Value

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Company Document No : RLE-2000-CPR-56123

Area : RAS LAFFAN EXPORT COMPRESSION

Discipline : CIVIL / EARTHWORK

Document Type : PROCEDURE

Contract Number : DC-PRM-581

Document Title : Method Statement for GRP / GRE Piping

File Name:RLE-2000-CPR-56123_C04 Page 1 of 32

File Name: RLE-2000-CPR-56123_C04 2of 32

File Name: RLE-2000-CPR-56123_C04 3of 32

2.0 HEALTH, SAFETY & ENVIRONMENT

3. Work site supervisor will be available on site at all times.

11. Method statement shall be approved by COMPANY.

COMPANY : Dolphin Energy Limited/DEL

File Name: RLE-2000-CPR-56123_C04 4of 32

CONTRACTOR : Larsen & Toubro Limited/L&T

5.0 SCOPE OF WORK

Wavistrong Installation Manual Rev 02

Fiberstrong Installation Guide for U/G Piping Systems, Rev 1

Fiberstrong A/G Piping System Selection & Installation Guide, Rev 1

ISO 14692 – Part 4, First edition 15-12-2002

File Name: RLE-2000-CPR-56123_C04 5of 32

Site QA/QC Procedures & Forms GRP/PJ/QM-01, Rev 6

GS EP PVV 178 – Design & Erection of GRP Piping Systems in DEL

7.1 General Requirements

 Certified FPI supervisor will be available at site.

7.2 Permit To Work

7.3 Handling & Storage

7.3.2 Storage of Material

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 Unprotected flange-faces shall never be placed directly on the ground or on concrete

 Resin and catalyst/hardener/adhesive shall be stored in original packing with caps

 Checklist “Storage Condition PJ/2P-1.1” on a daily basis to conform to proper stora.

7.4 Prefabrication of Spools on Site

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Internal Lamination is not applicable upto 600 mm.

Table 1 – Max. Dimensional Tolerances

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Fig 2 – Dimension numbers given in Table 1

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Table 2 –Tolerances for flange misalignment

7.5 Installation of Underground Pipe System

7.5.1 The Trench Construction

File Name: RLE-2000-CPR-56123_C04 10of 32

which may damage the pipe or cause stress concentrations.

Protective warning tapes shall be installed for protective grillage purpose.

 Trench Acceptance Report (ITP approved checklist)

7.5.3 Spools Laying

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 Adhesive Bonded Joint

7.5.4 Spool Jointing

7.5.4.1 Adhesive Bonded Joints

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Preparation for Bonding:

Do not touch the sanded surface after sanding and cleaning.

Bonding of the Joints

Or otherwise as indicated at detailed instructions supplied with Adhesives.

File Name: RLE-2000-CPR-56123_C04 13of 32

If the temperature is less than 20°C, warm the cement lightly.