Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.234.547

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No :
Project Rev.: E

Page 2 of 10

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
I

15.02.09

Company Comments Incorporated

SK

EO

AG

CCI

25.01.09

Issued for Review (As Required)

SK

EO

AG

IFR

05.11.08

Ready for Construction

SB

EO

AG

RFC

07.09.08

Issue for Review (Incorporated Linde Gama

meeting Comments 06.09.08)

SB

EO

AG

IFR

17.07.08

Ready for Construction

KC

EO

AG

ICC

29.06.08

Issued for Company Comments

KC

EO

AG

ICC

27.03.08

Issued for Company Comments

SB

UA

ZG

ICC

Issued for Review

SB

UA

ZG

IFR

Issued for Internal Review

SB

UA

ZG

IIR

GAMA
Rev.
No.

Project
Rev
No.

Date

Prepared Checked Approved

By
By
By
ORIGINATOR

Description

Status

Document Title:

LINDE ENGINEERING AG

QUALITY CONTROL PROCEDURE FOR U/G GRP

PIPING
Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470
GAM

PRO

QAC

GTL

030

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.234.547

Vendor Code

Rev No: E

Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

TABLE OF CONTENTS
1.

SCOPE ________________________________________________________________________ 5

2.

PURPOSE _____________________________________________________________________ 5

3.

REFERENCES _________________________________________________________________ 5

4.

DEFINITIONS _________________________________________________________________ 6

5.

RESPONSIBILITIES ____________________________________________________________ 7

6.

PROCEDURE __________________________________________________________________ 8
6.1.

GENERAL _______________________________________________________________________8

6.2.

INSPECTION _____________________________________________________________________9

6.3.

BELL & SPIGOT DOUBLE O- RING JOINT _________________________________________9

6.4.

LINK SEAL INSTALLATION ______________________________________________________10

6.5.

FLANGED JOINTS _______________________________________________________________10

6.6.

HYDROSTATIC TESTING ________________________________________________________10

T-4.234.547 Rev.E

Page 4 of 10

Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

1. SCOPE
This Quality Control procedure covers the inspections, tests, and examinations for which
records shall be produced, to document the conformance of site construction and installation
to the applicable approved drawings, specifications, codes, regulations and other contractual
documents.

2. PURPOSE
The purpose of this Quality Control Procedure is to detail all inspection and testing in order to
verify that GRP installation works confirm to project requirements and Flawless Start-up. This
procedure shall be read in conjunction with other related procedures where GRP installation
activity is an integral part thereof.

3. REFERENCES
T-4.234.547

: Quality Control Procedure for GRP Piping

T-4.234.567

: Method Statement for Road Crossing GRP

T-4.234.548

: Method Statement for Hydro-testing of U/G GRP Piping

T-4.240.925

: SARPLAST- GRP Installation, operation and maintenance manual

T-4.234.542

: Project Quality Plan

T-4.234.541

: Inspection & Test Plan for GRP Piping

T-4.219.611

: HSSE Procedure

T-13.376.808

: Project Specification for GRP Pipe lines & piping Systems

T-13.376.404

: General Arrangement of Manholes and Sumps

T-4.219.024

: List of Link-seal for Underground GRP-Piping

ASME B 16.5

: Pipe Flanges and Flanged Fitting

ASTM D-3262

: Standard Specification for Fiberglass Sewer Pipe

ASTM D-3517

: Standard Specification for Fiberglass Pressure Pipe

ASTM D-3754

: Standard Specification for Fiberglass Sewer & Industrial

Pressure Pipe

AWWA C-950

: Fiberglass Pressure Pipe

AWWA M-45

: Fiberglass Pipe design Manual

BS 5480

: British Standard Specification for Glass Reinforces Plastics

(GRP) pipes, joints and fittings for use for water supply or
Sewerage.

T-4.234.547 Rev.E

Page 5 of 10

Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

ISO 14692- Part-1 to 4 :

Petroleum and Natural Gas Industries glass reinforced plastics.

(GRP) piping

ISO 14692- Part-1 to 4:

Petroleum and Natural Gas Industries glass reinforced plastics

(GRP) piping.

ISO TR 10465 Part 1-3 Underground installation of flexible glass reinforced thermosetting
resin (GRP) pipes.
DEP 31.40.10.19-Gen

GRP Pipelines and Piping Systems

(Amendments / Supplements to ISO 14692)

4. DEFINITIONS
Company

QSGTL and/or its PMC

Contractor or Linde

Linde Engineering AG

Sub Contractor or Gama

Gama Qatar

Contract

QSGTL Pearl Plant - C2 ASU Construction Works

QCE

Quality Control Engineer

QCI

Quality Control Inspector

ITP

Inspection and Test Plan

QCR

Quality Control Records

QCP

Quality Control Procedure

TPI

Third Party Inspection

QA/QC

Quality Control / Quality Assurance

CS

Construction Supervisor

GRP

Glass Fibre Thermosetting Resin Polyester Pipe

GRV

Glass Fibre Thermosetting Resin Vinyl ester Pipe

T-4.234.547 Rev.E

Page 6 of 10

Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

5. RESPONSIBILITIES
Project Manager
The project manager shall be overall responsible to implement this procedure.
Site Manager
The site manager will provide inputs to the project execution plan.
Construction Manager
The Construction Manager is responsible for the over all management of the
project construction team to ensure that safe and effective operations are
conducted and properly documented.
Plant & Equipment Manager
The P & E Manager will be responsible for the all light and heavy machineries and
all tools related with GRP Piping Installation Works.
Site Engineer
SE should report to Construction Manager. Shall be responsible for planning,
execution and implementation of all site activities related to this procedure.
Site Foreman / Supervisor
Ensure that the work is carried out in accordance with project specification
drawings and related QCPs and ITPs.
Ensure that all preparations have been made as to the execution of the GRP
erection activity.
QA/QC Engineer
QA/QC E. shall report to Manager (QA/QC) and shall be responsible for overall
implementation, monitoring and control of QC activities.
QA/QC Inspector
Shall report to QA/QC Engineer. QCI shall responsible for attending all inspection
stages as required by ITP. And responsible to performing all checks and shall
prepare necessary Inspection Reports.
GRP PIPE MANUFACTURER / SITE REPRESENTATIVE
The manufacturer shall responsible for supply and providing the details of the
materials to be used for various types of joints, sequence of operation, safety
precautions to be followed and to provide initial set up & guide or training of sub
contractor pipe-jointers as required.
T-4.234.547 Rev.E

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Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

Before work commence, the manufacturer shall submit to the company a copy of
the training programme to be used to meet the requirements of T-13.376.808
(Section 6). Manufacturer should provide training and validate each inspector /
supervisor / pipe jointer as qualified.
The Manufacturers site representative shall be on site during all installation and
testing to supervise the work.
HSSE Manager
HSSE Manager shall report to Project Manager and responsible for overall control
and inspection of HSSE issues.
HSSE Officer
The HSSE officer shall report to HSSE Manager and shall responsible for
implementation of al safety aspects.

6. PROCEDURE
6.1.

GENERAL
Prior to starting of the work, GRP materials are approved as per specifications & GRP
manufacturers instructions only are used.
Ensure that the storing & Handling of GRP pipe, Piping components and all the joining
materials should be as per the manufacturer Instructions & accordance with ISO 14692
Part 4.
Be sure that the loading and unloading operations are done by the nylon slings only.
Ensure that the pipe handling & transportation shall be accordance with the
manufactures recommendation. Also Visual Inspection shall be carried out and recorded
in GAM-QCR-QAC-GTL-079 during receiving time.
If found any damage or fracture at the end portion of the GRP pipe, be sure to cut the
damaged part before lowering in to trench.
Make sure that the bell holes for joint locations shall be identified and correctly marked.
Ensure that the all types of joints should be carried out by only qualified person used,
with proper training given by Manufacturer.
Earth Work Excavation shall be carried out as per E W E procedure, recorded in QCR #
GAM-QCR-QAC-GTL-050 and approved by CONTRACTOR and COMPANY.
The Quality control inspector visually inspected the joint & makes a visual inspection test
report # GAM-QCR-QAC-GTL-045 for Atm. Condensate line. For Fire fighting and AOC
lines, GAM-QCR-QAC-GTL-045 shall be prepared during nipple test.
The Site Engineer / Inspector will raise the Request for Inspection (RFI), as required &
make initial /prepare the necessary documents related to activity & submitted to
Contractor Quality Department prior to start of the activity.

T-4.234.547 Rev.E

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Q A T A R

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

Ensure that the safety PPEs are properly followed during inspection of construction works
and in live systems.

INSPECTION

6.2.

Inspection shall be executed fully in accordance with T-13.376.808 Project Specification for
GRP Lines and Piping Systems and the following:
Identification of piping section after prefabrication shall be performed and the spool number,
line number shall be painted on each spool piece
Whether the piping system has been fabricated in conformance with relevant spool drawing.
Ensure that there is no twist in the piping system, and that the piping is horizontally and
vertically correct
Plumb and levelness are correct.

BELL & SPIGOT DOUBLE O- RING JOINT

6.3.

Make sure that the rubber is not damaged and insertion is completed.
The piping joints of bell & spigot joints shall be tightness tested direct after joint completion
and piping alignment. This means hydrostatic testing of the annular space between the bell
& spigot (between the two O-rings) through the threaded test nipple connection on the
outside of the bell. This test shall be fully in accordance with Manufacturers
recommendations.
The test pressure is normally 5 bars and the holding time is minimum 5 minutes. If no
leakage found, the joint is accepted and the test hose connection can be removed and the
test hole plugged. PTFE tape shall be used for proper plug sealing. The test is now
completed and the next joint can be made.
Each joint shall be permanently marked for identification purpose. A logbook containing key
values relevant for the jointing process shall be maintained. The key values:
i.
ii.
iii.
iv.
v.

Name and Badge Number

Unique Joint Number
Date of Jointing
Inspection Date
Inspectors Name

Nipple Test inspection is completed and recorded in QCR # GAM-QCR-QAC-GTL-045.

T-4.234.547 Rev.E

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Q A T A R
6.4.

Doc. Title

GAM-PRO-QAC-GTL-030 Rev. I
Quality Control Procedure for U/G GRP Piping

Date

15.02.2009

LINK SEAL INSTALLATION

Make sure pipe is centered.
Install the belt with pressure plates evenly spaced
Install the exact number of links indicated in sizing charts.
Check to make sure pipe is supported properly during backfill operations.
Make sure seal assembly and pipe surfaces are free from dirt.
Dont install the belt with pressure plates aimed in irregular directions
Dont install Link-Seal Modular seals with spiral weld pipe.
Dont torque each bolt completely before moving on the next.
Dont use high speed power tools.
Please note that the Link-Seal is not fixing point.

6.5.

FLANGED JOINTS
Make sure that all bolts are tightened properly and torque values are recorded in QCR#
GAM-QCR-QAC-GTL-041.
Final inspection for verticality, face gap, parallelism and centre line offset is completed and
recorded in QCR # GAM-QCR-QAC-GTL-142.

6.6.

HYDROSTATIC TESTING
The Hydro test will be carried out as per the project Quality specification # T-13.376.808 and
& as per the GRP manufacturers recommendations and T-4.234.548 recorded in Linde
Piping Record (R02). Test Manifold will be tested and recorded.
Ensure that the Joint history record should be maintained against each isometric with all
details.

T-4.234.547 Rev.E

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