General Product Repair

Guidelines

Client: SONATRACH SPA/ACTIVITE TRANSPORT PAR CANALISATION

(TRC)
Project: ACQUISITION DE 47 000 ML DE TUBES DIAMETRE 24’’ EN FIBRE DE VERRE (GRE) DESTINES
AU
PROJET DE REHABILITATION DE L’OLEODUC OH1 « IN AMENAS – HAOUD EL HAMRA »

End User: SONATRACH SPA/ACTIVITE TRANSPORT PAR CANALISATION

(TRC)

Document Number: FPI-AUH-FSV-MS-SONA-OHPR-GPRG

Revision: 0

Field Services Department

Revision & Approval Control

DOCUMENT CONTROL

Document Number FPI-AUH-FSV-MS-SONA-

OHPR-GPRG
Title General Product Repair Guidelines

Issue Date 25-01-2022

REVISION CONTROL

Revision Date Description Comments

0 25-01-2022 For review N/A

APPROVALS

Name Position Signature Date

PREPARED BY

Name Position Signature Date

Mohammad 25-01-2022
Field Services Engineer
Hammoud

REVIEWED BY

Name Position Signature Date

Alaa Rawas Field Services Manager 25-01-2022

Page 2 of 11
TABLE OF CONTENTS
1. GENERAL............................................................................................................................. 4
2. QUALITY .............................................................................................................................. 4
3. INSPECTION......................................................................................................................... 4
4. MATERIALS, TOOLS, AND CONSUMABLES ......................................................................... 4
5. REFERENCE ......................................................................................................................... 6
6. REPAIR PROCEDURE ........................................................................................................... 6
7. HSE REQUIREMENT ............................................................................................................ 10
8. RISK ANALYSIS ................................................................................................................... 10
9. ATTACHMENTS .................................................................................................................. 11

Page 3 of 11
1. GENERAL
This document describes the procedures for repair and field rectification that can be
followed in the event of damage occurring in a piping component after delivery. All
personnel involved in the procedure must be familiar with and fully understand the
techniques described in this document to ensure efficient repair.
Damage to the Glass Reinforced Epoxy (GRE) components due to external factors are
rarely identical. Any damage shall be analyzed on a case by case basis, and a specific
repair procedure applied to each situation. Some of the frequently occurring damages are
explained in this document. Any damage not addressed in this document shall be
investigated by a Future Pipe Industries field representative and a customized repair
procedure shall be advised by the Future Pipe Industries technical team following a
detailed analysis. Any deviation made in this document shall be documented and
approved by the Client.
Instructions in this document are complete to the extent possible. However, Future Pipe
Industries’ experienced Representatives or Engineers may opt for an alternative or optimum
solution for the issues not addressed in this document. The latest techniques, industry
standards, and sound engineering practices shall always be followed.
Future Pipe Industries Engineers or Representatives shall be consulted for any clarifications or
statements made in this document.
Definition of words used in these instructions:
- The word “shall” indicates a requirement.
- The word “should” indicates a recommendation.

2. QUALITY
The Personnel who carry out the repair shall possess a valid Bonder Qualification Certificate
issued by Future Pipe Industries.

3. INSPECTION
All pipes, fittings or components used in the piping system shall be inspected for damages,
prior to the installation activity. Rejected items shall be separated and quarantined from
undamaged materials to avoid unintentional use. Damaged or defective material must not
be used before it is repaired or replaced.
Ensure all necessary tools and materials are available prior to performing any repair activity.

4. MATERIALS, TOOLS, AND CONSUMABLES

The following materials, tools, and consumables required during the repair activity. The
minimum required tools shall be selected based on the type of defect and the repair
methodology to be adopted.

Page 4 of 11
4.1 Materials
• GRE Lamination Materials as per recipe.
• TB/TB Coupler (for applicable cases)
• Adhesive Kit. (for applicable cases)
4.2 Tools
• Heating blanket (plus temperature controller)
• Shaving Machine (for applicable cases)
• Tapeline
• Measuring tape and/or folding rule, Pi tape, Curve-o-mark, Steel roller
• Pipe fitter’s wrap-around
• Level and marker
• Pipe vice or stable supports (brackets) with a rubber-coated clamping device
• An angle grinder, Cutting Disc, Disc grinder or Power jigsaw
• Small electrical or air-driven grinding machine
• Insulation material or blankets
• Digital temperature gauge for surface temperature measurement
• Dew point meter
• Thermometer
• Relative humidity meter
• Hot air blower
• Calibrated Weighing scale
4.3 Consumables
• Emery disks (grade P40 to P60).
• 4” Diamond cutting disc
• Plastic Bucket
• Masking tape
• Tarpaulins
• Marker pen
• Dust (paint) brush
• Lamb wool roller, lamb wool refill
• Spatula (rubber scraper plate, filling knife)
• Rubber gloves, Cotton Gloves
Page 5 of 11
 • Working gloves
• Polyethylene gloves
• Dust masks, Safety goggles
• Overalls, safety shoes, safety helmet
• Cleaning rags, cleaning fluid such as acetone, Methyl Ethyl Ketone (MEK) or
Methyl Iso Butyl Ketone (MIBK)

5. REFERENCE
1. Relevant joint method statements.
2. User manual for tools and equipment.
3. Approved drawings in case of a major repair.

6. REPAIR PROCEDURE
Defects are the visual imperfections on the pipe body that may or may not affect the
performance of the product. Damages during the handling and transportation that listed in
below table.

Type of Damages and Repair Methods

Sl. Type of damage Definition Repair Method
No.
1 Impact Damage -Damage to the pipe structural wall. Depend on the damage depth ( Method
to the pipe body -Crack or Craze of surface 01, Method 02 or Method 03)
2 Impact Damage -Pipe end damage The respective section shall be cut and
to the Spigot a new TS shall be calibrated.
end
3 Delamination Separation of laminate layers by Depend on the damage depth ( Method
(External) external factors at the pipe exterior 01, Method 02 or Method 03)
surface
4 Liner Damage Defects on the pipe internal liner Damaged area can not be repaired,
(Internal) defected portion shall be cut and
removed as per repair method 03.
5 The pipe Pipe structural damage No Repair allowed- Replace the item
dropped from a
height
6 Fire/Burning Pipe burned due to fire. No Repair allowed- Replace the item

6.1 Minor Repair

Minor defects or damage are repairable on-site as per the below guidelines. 3 types of
repair are detailed below based on the intensity of the damage.

Page 6 of 11
6.1.1 Repair Method-1, Patch Lamination.
This method covers defects depth up to 1mm from the pipe surface.
1) Locate and mark the repair area by a maximum of 70x70 mm.
2) One patch lamination of 70x70 mm is intended to cover a maximum of 50 mm
defect length. In case the defect length is more than 50 mm, multiple numbers of
patch lamination shall be considered.
3) Grind and remove the topcoat of the repair area as marked using an emery disc
slowly to get good control on the grinding area and to avoid excessive grinding on
the pipe structure.
4) Clean and remove the dust from the ground area.
5) Use the masking tape to define repair area limits.
6) Apply C-veil and Resin mix as per the recipe.
7) Apply resin coat without the C-veil reinforcement if the defects are less than 0.30
mm.
8) Cure the repaired surface by using a hot air blower.
6.1.2 Repair Method-2, Overlay lamination.
This method covers defects depth 1 to 2 mm from the pipe surface. The maximum length or
width of scratch is limited to 100 mm. Maximum 2 numbers of such repairs are allowed in
one standard length of pipe.
The defects having length or width more than 100 mm, Future Pipe Industries Engineers or
Representatives shall be consulted for further guidelines.

Field Overlay Lamination

1) Locate and mark the repair area by a maximum length of 300 mm circumferentially
by using a pipe fitter’s wrap-around. The defective area shall be kept at the center.
2) Grind the surface area using an emery disc slowly to get good control on the
grinding area and to avoid excessive grinding on the pipe structure.
3) Once the defective area is removed from the pipe, Clean and remove the dust from
the ground area. Use cotton rags to clean the ground area.
4) Use the masking tape to define lamination area limits.

Page 7 of 11
 5) Mix the resin and hardener as per the quantities specified in the recipe to maintain
the right mixing ratio.
6) Wet the bonding surface with the resin and hardener mixture.
7) Apply one layer of woven roving glass over the wet surface and Impregnate by
lamb wool rollers dipped in resin and hardener mixture.
8) Repeat the process until the required number of layers are applied as per the recipe
including sealing layers.
9) Wind top tape as per recipe over the laminate surface to extract the excess resin,
and to provide a smooth surface.
10) Once the laminate is tack free, wrap a heating blanket over the laminated surface.
Secure the blanket in place with any non-conductive material.
11) Set the temperature controller at 125°C and cure the lamination for a minimum
duration of 1.5 Hours.
12) Cover the heating blanket with a suitable insulating material (fire blanket or
equivalent). If there is an overlap of the heating blanket, the overlap portion shall
be insulated and it shall be outside of the insulating material to avoid overheating
and discoloration.
6.1.3 Repair Method-3, Defective section Replacement.
For defects more than 2 mm depth from the pipe outer surface, the damaged pipe section
shall be cut and discarded. After removing the defected section, the remaining pipe
sections can be joined together by using a TB/TB adhesive coupler or Field Constructed
Coupler Joint.
This repair method is also applicable for pipe internal damage to the liner where no other
repair is applicable.
1) Locate the defected area and mark the pipe for cutting by using a pipe fitter’s wrap-
around.
2) Cut the pipe section by using a diamond or carbide coated abrasive wheel. The
defected cut section shall be separated and quarantined from undamaged pipes to
avoid unintentional use.
3) Check pipe ends after cutting and ensure it is free from damages. Also, ensure that
the squareness of the cut ends remains within the required tolerance.
4) Shave the pipe ends using a shaving machine.
5) Join the pipe sections by using a TB/TB Coupler or Field constructed Coupler joint as
per the below repair diagram. Refer project specific TB/TS adhesive / FCC method
statements for the detailed joint instructions.

Page 8 of 11
Repair Diagram - Repair using TB/TB Coupler (Option 01)

Repair Diagram – Repair using FCC Joint (Option 02)

Page 9 of 11
7. HSE REQUIREMENT
The HSE Management plan establishes standards to minimize the risks to health and the
environment, to prevent work accidents and to define the minimum (mandatory) hygienic
and health facilities required in the construction field, including those required for
environmental protection, throughout the execution of Fieldworks.

8. RISK ANALYSIS
a. Individuals falling to a different level

I. Collective systems and organizational measures

• Clean work areas
• Mark the trench with adequate signposting
• Verify the stability of hoisting elements
• Use of scaffolds when needed
• Scaffolds shall be erected and modified only by authorized and trained
personnel
• Lifting machinery shall be handled only by authorized and trained personnel
• Attach the harness to basket lower handrail while using boom and scissor lifts.
II.PPE: Use of safety harness attached to a fixed point, use of life-line if required

b. Individuals falling to the same level

I. Collective systems and organizational measures

• Clean work areas
• Housekeeping to be maintained
II.PPE: Safety shoes

c. Stepping on objects

I. Collective systems and organizational measures

• Clean work areas
• Housekeeping to be maintained
II.PPE: Safety shoes

d. Projection of particles

I. Collective systems and organizational measures

• Tools must be in perfect condition
• The operator must be trained on handling the tools to operate them
II.PPE: Safety goggles, safety gloves, work clothing, and safety helmet

e. Explosion

I. Collective systems and organizational measures

Page 10 of 11
 • Avoid flammable materials (resins, acetones) entering in contact with fire or hot
elements
• Prohibit smoking while carrying out this type of work
• Ease ventilation of the workplace and the interior area of the pipe with
extractors (in the case of internal jointing), (Explosion Proof unit)
• Verify possible reactions between different chemical agents before joining
physically
• Proper lighting equipment
II. PPE: Safety goggles and gloves, and work clothing

f. Exposure to chemical agents by inhalation

I. Collective systems and organizational measures

• Carry out joints in ventilated areas
• Verify possible reactions between different chemical agents before joining
physically to avoid giving off gases
• Ease ventilation in the interior area of the pipe with extractors (in the case of
interior joining)
I. PPE: Respiratory protections (filter mask)

g. Thermal contacts

I. Collective systems and organizational measures

• Demonstrate and indicate to Field operators that the laminated jointing method
produces a high-temperature reaction
II. PPE: Safety gloves

h. Electrical contacts

I. Collective systems and organizational measures

• Do not work in damp areas
• Verify the condition of tools' insulating elements
• Verify protection against direct and indirect contacts of electrical elements
• All electrical equipment and tools should be inspected and tagged.
II. PPE: Safety gloves

9. ATTACHMENTS
A. Recipe.

Page 11 of 11