Vv216a-109-A-807 - 12 - 0001 - Laminator's Training Procedure

SHEET 1 OF 27
Vendor's name Future Pipe Industries – Abu Dhabi
P.O. No.: 0-6798-PJ216A-109-A110_00
ITEM No.: All
ITEM NAME: GRE/GRV & GRP Piping
DOCUMENT TITLE:
Laminator's training procedure
VENDOR's Doc. No.: AI-1133-FPI-DW-CFP-TP
KNPC CLEAN FUELS PROJECT
Next revision
should be "AB"
Vendor
ISSUE PURPOSE:
□FA □FR □FI □FC □AB
Approval or review hereunder shall not be construed to relieve Vendor /
Subcontractor of his responsibilities and liability under the Contract.
CTR DEPT. /
Contractor Review Result
SIGNATURE
1. Approved / No Comments CNS /
2. Approved / Reviewed - Minor Comments PIP : H.Suzuki
Venkat.S /
3. Rejected - Comments as Noted N.Yoshimoto
4. Rejected
QC-Gupta
5. Not Reviewed
JOB. NO 0-6798-2 Doc Type Code P40
COMPANY REV
DOC.no. VP-PV216A-109-A-000-P40-007
V plus Purchaser Code (V/J/G/S) & Purchase Order No. - SERIAL no.
Conctractor
12
DOC.no. VV216A-109-A-807
Next revision "13"
D R A
IN6-SEP- 6
0
2 0 1
Kuwait National Petroleum Company (K.S.C.) VP-PV216A-109-AA-000-P40-007
Clean Fuel Project (CFP) Rev. 12
KNPC Contract No. CFP/EPC/0054-MAA Page 2 of 19
Contractor Job Code: 0-6798-20-0000 VV216A-109-A-807
PROJECT / CONTRACT REF.:
KNPC Clean Fuels Project
DOCUMENT TITLE :
Training & Qualification Program for

Adhesive Bonded (TB/TS) & Straight Field
Lamination of GRE/GRV Pipes & Fittings
4-Sep-16 12 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
1-May-16 11 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
18-Apr-16 10 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
9-Dec-15 9 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
30-Jul-15 6 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
7-May-15 5 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
21-Apr-15 4 ISSUED FOR REVIEW REMUS ORASA MARK BACUS
REV.
DATE NO. REASON FOR REVISION Prepared Review & Approved
Note: JGSK document review result will be reflected on the cover page.
DOC NO. FPI-SS-CFP-TQP
R A
CLIENT: JGSK Joint Venture
D
N
I 06-SE 6
P - 2 0 1
Training & Qualification Program for Adhesive

Bonded (TB/TS) & Straight Field Lamination of
GRE/GRV Pipes & Fittings
CONTENTS
A. Scope of Work
B. Purpose
C. Reference
D. Manpower/ Crew
E. Training Course
F. Training Register
G. Assessment
H. Test Results & Certificates
I. Training Materials
J. HSE Requirement
K. Attachments
Project Client Doc. Title Doc. No.
KNPC – Clean Fuels Training & Qualification

JGSK Joint Venture FPI-SS-CFP-TQP
Project Program
D R A Date Printed: 4-Sep-16
N
I 6-SE 6
0
P - 2 0 1

A. Scope of Work
The scope of work covers the supply of Training instructor and Technician to train
and familiarize Contractor’s crew of KNPC Clean Fuel Project on the procedures
and techniques of performing Adhesive Bonded Joints (TB/TS), Lamination Joints
(LJ) and Flange Jointing prior to their actual execution at site.
Training will be conducted in seven days per session at a given site in Kuwait.
Number of session depends on the number of participants and one session
should not exceed 24 participants.
B. Purpose
The purpose of this training program is to obtain required skills to become a

qualified fitter, supervisor and inspector on the standard procedures and
techniques for Adhesive-bonded (TB/TS), Straight Field Lamination and Flange
Assembly of GRE pipe prior to actual joint and spool production. Each qualified
joint diameter (D) also qualifies smaller size joints to 0.5D. The personnel shall
be trained as per the outlines below and later assessed by means of written
examination and practical assessment as per DEP 31.40.10.19-Gen Section 9 &
Appendix A and ISO 14692-4. Candidates shall be satisfactory in physical
condition, eyesight, qualification and experience requirement as per ISO 14692-
4.
C. Reference
1. ISO/FDIS 14692-4 (Petroleum and Natural Gas Industries – Glass Reinforced

Plastic Piping)
2. Shell DEP 31.40.10.19 - Gen (Glass-fibre Reinforced Plastic Pipeline & Piping
System) – For Pressure Piping
3. Shell DEP 34.14.20.31 - Gen (Drainage Systems & Primary Treatment

Facilities) – For Non-Pressure Piping
4. VP-PV216A-109-A-000-P40-005 (Field Fabrication Procedure)

Project Program
N
I 6-SE 6
0
P - 2 0 1

D. Manpower/ Crew
The contractor shall depute not more than 24 technicians per training session
which will be divided into groups with assigned crew leader in each group. The
crew leader shall be responsible for the technicians and the main point of contact
during the training. Number of persons per crew shall be as per the attached
training plan. Additional one (1) or two (2) participant(s) can be accommodated in
a crew depending on the diameter size of the training test spool
E. Training Course
The contractor crew, selected by the company/contractor from his workforce,

shall be trained on the following courses.
1. Proper Handling & Storage (Theory)
A course shall be conducted in proper handling and storage GRE materials
Schedule : Day 1
Time : 8:00am to 5:00pm
Attendees : JGSK Personnel (supervisors/workers assigned to this work)
2. Tools, Raw Materials & Consumables (Theory)
A course shall be conducted in using the tools, raw materials and consumables
required to prepare and join the pipe ends. The tools, raw materials and
consumables shall be identified and presented one by one. The safety shall be
briefly explained at the same time of presentation.
The instructor shall demonstrate and the crew leader shall be required to perform
the same with the assistance of technician.
The tools and consumables required are listed below.
SN Description Remarks
1 Shaver Machine - (TB/TS) applicable sizes To be provided by JGSK
2 Heating Blankets - applicable size To be provided by JGSK
3 Wrap around tape (all applicable sizes) To be provided by JGSK
4 Curve-o-mark To be provided by JGSK
5 Pi tape To be provided by JGSK
6 Spirit level To be provided by JGSK
7 Pipe vice/ Working table To be provided by JGSK

Project Program
N
I 6-SE 6
0
P - 2 0 1

8 4” Angle grinder To be provided by JGSK

9 Grinding disc with backing pad To be provided by JGSK
10 Cutting disc 4” To be provided by JGSK
11 Drilling machine To be provided by JGSK
12 Rubber mandrel To be provided by JGSK
13 Emery cup To be provided by JGSK
14 Hand gloves To be provided by JGSK
15 Marker pen To be provided by JGSK
16 Paint brush 3” To be provided by JGSK
17 Come along Jacks To be provided by JGSK
18 Rubber pad – 5mm thick To be provided by JGSK
19 Latching belts To be provided by JGSK
20 Rubber hammer To be provided by JGSK
21 Pipe Clamps To be provided by JGSK
22 Safety glasses To be provided by JGSK
23 Blind flanges (applicable diameter) To be provided by JGSK
24 Calibrated torque wrench and sockets To be provided by JGSK
25 Gaskets, bolts, nuts and washers To be provided by JGSK
26 Testing manifolds To be provided by JGSK
27 Pressure pumps & pressure gauge To be provided by JGSK
28 Cement kit – for 1 training session only To be provided by JGSK
29 Lamination kits - for 1 training session only To be provided by JGSK
Schedule : Day 1
3. Reading & Comprehension (Theory)
A course shall be conducted in reading and comprehending the isometric

drawings to determine their ability in identifying piping components of the line,
type of joints, general orientation and location of the line.
Schedule : Day 1
4. Fabrication and Jointing (Practical)
The joint making and testing should be witnessed by a recognized Accreditation /

Inspection Agency (e.g. Lloyd, DNV, TUV, or Velosi) to be agreed by the
Principal (Para.A.5 of Appendix A of DEP 31.40.10.19-Gen.)

Project Program
N
I 6-SE 6
0
P - 2 0 1

The crew leader and technicians shall be required to perform the actual jointing
spool fabrication. The course outline shall be as follows.
1. Cutting of pipes
2. Calibration using shaver machine
3. Grinding using angle grinder & drill machine
4. Cement mixing and application
5. Joint assembly – TB/TS & Lamination Jointing (LJ)
6. GRE adhesive-bonded saddle & GRV laminated saddle
7. Joint curing using heating blankets
8. Bolt torqueing sequence
Depending upon the performance of the crew leader and technicians, FPI
instructor shall at his own discretion extend the duration of this exercise.
Schedule : Day 2, 3, 4, 5 & 6

5. Hydro testing
1. Fix the end closures to the test spool.

2. The test spool shall be filled with water ensuring that no air is entrapped.
3. The test spool shall be pressurized uniformly and continuously to the required
test pressure (3 x Design Pressure) and hold for 1 hour.
4. Monitor the test pressure during the test period.
Notes:
 Test spools can only be tested one time and cannot be reused.
 Multiple spool shall not be connected together and tested. (If multiple
spools are tested together and any spool failed, all connected spools are
failed and cannot be tested anymore)
Schedule : Day 6 & 7

F. Training Register
All trainees shall be required to register during the course of training in the
attendance sheet.

Project Program
N
I 6-SE 6
0
P - 2 0 1

G. Assessment
Contractor’s personnel shall be assessed in their performance of the skills they are
required to perform. The technician shall sign a form to acknowledge their
understanding of the required skills.
H. Test Results & Certificates
The test shall be recorded on the spool fabricated and tested by JGSK Personnel.
The criteria are as follows.
1. The crew leader and technicians shall be considered qualified to jointing if the
joints fabricated passed the required test pressure. If any of the joints failed,
one additional test is permitted. If the second test fails, no further test are
permitted.
2. Successful crew leader and technicians shall be provided with certificates

from FPI. The crew who failed will be at the discretion of the contractor to
request similar training at own cost.
3. The joint shall be examined in accordance with the joint specification. The
result shall satisfy the requirements laid down in the specification, including
dimensions, tolerances, Tg glass fibre content.
4. The test piece (sample) shall be visually assessed in accordance with ISO
14692-4:2002, Annex A. each test joint shall be cross-sectioned and the cut
surface examined using an optical microscope.
 The above No. 3 & 4 assessments are to be done at FPI Laboratory.
5. FPI will issue certificates to the successful participants with the following
information:
5.1 Full name of the qualified technician

5.2 Date of qualification and period of validity
5.3 Limitations within which the certificate is valid such as type of material
type of joint, diameter range, pressure range, etc.
5.4 Name and signature of the trainer and vendor company stamp

Project Program
N
I 6-SE 6
0
P - 2 0 1

I. Training Materials
1. GRE Materials for demo, practice and test spool will be provided by JGSK.
2. Tools and consumables and testing manifolds including blind flanges, bolts,
nuts and pumps shall be arranged by JGSK.
J. HSE Requirement
1. While cutting, grinding and laminating, the following personal protection shall
be used to avoid skin irritation and inhaling dust.
1.1 Dust mask

1.2 Safety glasses
1.3 Hand gloves
1.4 Coverall
1.5 Safety shoes
1.6 Safety helmet
2. The chemicals are potentially flammable. Resins and hardeners must be

stored in a dry area away from direct sunlight and fire hazards.
3. SMOKING is not allowed in all areas where lay ups are being made and fire
extinguisher should be available near by the layup area.
4. If required, technicians will wear fume mask (e.g. 3M Half Face Respirator-
6000 Series with 3M Cartridge 6000 Series) to protect from fumes and
chemical smell.
5. Follow any safety rules as strictly enforced of the end users and the client.
K. Attachments
1. Training Plan
2. List of tools and consumables
3. Training certificate (sample)

Project Program
N
I 6-SE 6
0
P - 2 0 1
Kuwait National Petroleum Company (K.S.C.) VP-PV216A-109-A-000-P40-007
Clean Fuels Project (CFP) 2
08
09
10
11
Rev. 12
Training and Qualification Plan
Project: KNPC Clean Fuel Project

Location: Kuwait
Contractor: JGC Corporation
TRAINING DETAILS
Type of Jointing Adhesive-Bonded (TB/TS) & GRE/GRV Lamination
Training Qualification Adhesive-Bonded (TB/TS), Straight Field Lamination of GRE/GRV Pipes and Fittings
PROPOSED TEST SPOOL

Adhesive-Bonded Joint (TB/TS) & GRE Lamination DN150, Design Pressure = 16.0 Barg
Test Spool No. 1

TB/FF Flange TB/FF Flange
GRE Lamination
Total: 4 person per spool
Test Spool No. 2

GRE Lamination
GRV Lamination DN50, Design Pressure = 16.0 Barg
Test Spool No. 3
GRV Lamination
D R A
N
I 06-SEP 6
- 2 0 1
R Rev. 11
Clean Fuels Project (CFP) Rev. 10
08
09
12
Rev.11
GRE Lamination DN700, Design Pressure = 16.0 Barg
Test Spool No. 4
GRE Lamination
Test Spool No. 5
GRV Lamination
SUMMARY OF MATERIALS
Hydrotest Pressures 3 x Design Pressure (Shell DEP 31.40.10.19)
Test Spool No. 1, 2, 3 & 4 48.0 barg
Test Spool No. 5 30.0 barg
D R A
N
I 06-SEP 6
- 2 0 1
08
09
10
11

Location: Kuwait
Contractor: GS Engineering & Construction
TRAINING DETAILS
PROPOSED TEST SPOOL

Test Spool No. 1

GRE Lamination
Test Spool No. 2

GRE Lamination
Test Spool No. 3
GRV Lamination
D R A
N
I 06-SEP 6
- 2 0 1
08
11
09
10
Test Spool No. 4
GRV Lamination
GRV Lamination DN800, Design Pressure = Gravity (1 Barg)
Test Spool No. 5
GRV Lamination
Test Spool No. 1, 2, 3 & 4 48.6 barg
Test Spool No. 5 3.0 barg
D R A
N
I 06-SEP 6
- 2 0 1
09
10
11

Location: Kuwait
Contractor: SK Engineering & Construction
TRAINING DETAILS
PROPOSED TEST SPOOL

Test Spool No. 1

GRE Lamination
Test Spool No. 2
GRV Lamination
Test Spool No. 3
GRV Lamination
D R A
N
I 06-SEP 6
- 2 0 1
10
12
11
Test Spool No. 4

GRE Lamination
Test Spool No. 5 Shop Joint GRV Lamination
Test Spool No. 6

GRE Lamination
Test Spool No. 1 to 6 48.0 barg
D R A
N
I 06-SEP 6
- 2 0 1
JGSK
Clean Fuels Project
LIST OF TOOLS & CONSUMABLES
Adhesive Bonded (TB/TS)
A. Tools
1. TS shaving machine – 25mmØ to 150mmØ
4. Heating blanket – 150mmØ
8. 4” Angle grinder
9. Drill machine
10. 50m long electrical cables with industrial plug
11. 2” nylon / canvass binders with hook
12. 2” nylon / canvas belt
13. Hand pullers cable type
14. Come along jack
15. Rubber mallet, medium
16. Pipe fitter’s wrap around
17. Spirit level
18. 25mmØ to 300mmØ PI tape
19. Measuring tape, 5m
20. 12” right angle
21. Scissors
22. Wavistrong adhesive kits
B. Consumables
1. Hard cotton gloves
2. Polythene gloves
3. Emery paper
4. Emery cups
5. Rubber mandrel
6. 4” grinding disc, grit 40-60
7. 4” diamond cutting disc
8. Dust Mask (3M Particulate Respirator 8000 Series)
9. Permanent marker
10. Paint brush, 4”
11. Cotton rags
D R A
N
I 06-SEP 6
- 2 0 1
JGSK
Clean Fuels Project
GRE Lamination Jointing
A. Tools

10. Spirit level
13. Scissors
14. Lamination kit
B. Consumables

2. Polythene gloves
3. Emery paper
7. Permanent marker
9. Cotton rags
10. Plastic bucket
11. Lamb wool roller
12. Roller refill
13. Disposable coverall
14. Digital weighing scale
15. Steel roller
D R A
N
I 06-SEP 6
- 2 0 1
JGSK
Clean Fuels Project
GRV Lamination Jointing
A. Tools
6. Spirit level
9. Scissors
10. Lamination kit
B. Consumables

2. Polythene gloves
3. Emery paper
7. Permanent marker
9. Cotton rags
10. Plastic bucket
11. Lamb wool roller
12. Roller refill
13. Disposable coverall
14. Digital weighing scale
15. Steel roller
D R A
N
I 06-SEP 6
- 2 0 1
Clean Fuels Project (CFP) 09
10
08
Rev. 1
Contractor Job Code. 0-6798-20-0000 VV216A-109-A-807
SAMPLE
SAMPLE
D R A
N
I 06-SEP 6
- 2 0 1
Training and Qualification Plan 2
Location: Kuwait
Contractor JGC Corporation
TRAINING DETAILS
Adhesive-Bonded (TB/TS) & Straight Field Lamination of GRE/GRV Pipes and Fittings
Training Qualification DIAMETER: 25mm up to 700mm for GRE/GRV Pipes & Fittings with Design Pressure up to 16 Bar,
750mm up to 1200mm for GRE/GRV Pipes & Fittings with Design Pressure up to 10 Bar
PROPOSED TEST SPOOL

Test Spool No.1
TB/FF Flange
TB/FF Flange GRE Lamination
ND 150

1000 1000
Test Spool No.2
TB/FF Flange GRE Lamination TB/FF Flange
ND 300

1500 1500

Test Spool No.3
GRV Lamination
ND 50

300 700 700 300
D R A
N
I 06-SE 6
P - 2 0 1
Test Spool No.4
GRE Lamination
ND 700

1500 1500

Test Spool No.5
GRV Lamination
ND 150
Total: 4 person per spool 1000

1000

Test Spool No.6
GRE Lamination
ND 1200

1000 1000
D R A
N
I 06-SE 6
P - 2 0 1
Location: Kuwait
TRAINING DETAILS
Training Qualification DIAMETER: 25mm up to 700mm for GRE/GRV Pipes & Fittings with Design Pressure up to 16 Bar,
750mm up to 1200mm for GRE/GRV Pipes & Fittings with Design Pressure up to 10 Bar
PROPOSED TEST SPOOL

Test Spool No.1
GRE Lamination TB/FF Flange
TB/FF Flange
ND 150
1000
Test Spool No.2
ND 300

1500 1500

Test Spool No.3
GRV Lamination
ND 50

300 700 700 300
D R A
N
I 06-SE 6
P - 2 0 1
Test Spool No.4
GRE Lamination
ND 700

1500 1500

Test Spool No.5
GRV Lamination
ND 300

1000 1000

Test Spool No.6
GRE Lamination
ND 1200

1000 1000
D R A
N
I 06-SE 6
P - 2 0 1
Location: Kuwait
TRAINING DETAILS
Training Qualification
DIAMETER: 25mm up to 700mm for GRE/GRV Pipes & Fittings with Design Pressure up to 16 Bar
PROPOSED TEST SPOOL

Test Spool No.1
TB/FF Flange
TB/FF Flange GRE Lamination
ND 150

1000 1000
Test Spool No.2
ND 300

1500 1500

Test Spool No.3
GRV Lamination
ND 50

300 700 700 300
D R A
IN6-SEP- 6
0
2 0 1
Test Spool No.4
GRE Lamination
ND 700

1500 1500

Test Spool No.5
GRV Lamination
ND 150

1000
D R A
IN6-SEP- 6
0
2 0 1
Location: Kuwait
TRAINING DETAILS
Training Qualification
DIAMETER: 25mm up to 700mm for GRE/GRV Pipes & Fittings with Design Pressure up to 16 Bar
PROPOSED TEST SPOOL

Test Spool No.1
GRE Lamination TB/FF Flange
TB/FF Flange
ND 150
1000
Test Spool No.2
ND 300

1500 1500

Test Spool No.3
GRV Lamination
ND 50

300 700 700 300
D R A
IN6-SEP- 6
0
2 0 1
Test Spool No.4
GRE Lamination
ND 700

1500 1500

Test Spool No.5
GRV Lamination
ND 300

1000 1000
D R A
IN6-SEP- 6
0
2 0 1

Vv216a-109-A-807 - 12 - 0001 - Laminator's Training Procedure

Uploaded by

Copyright:

Available Formats

Vv216a-109-A-807 - 12 - 0001 - Laminator's Training Procedure

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Vv216a-109-A-807 - 12 - 0001 - Laminator's Training Procedure

Uploaded by

Copyright:

Available Formats

What is the purpose of the training program?

What is the purpose of the training program?

What types of joints will be covered in the training?

What types of joints will be covered in the training?

SHEET 1 OF 27

Vendor's name Future Pipe Industries – Abu Dhabi

P.O. No.: 0-6798-PJ216A-109-A110_00

ITEM No.: All

ITEM NAME: GRE/GRV & GRP Piping

VENDOR's Doc. No.: AI-1133-FPI-DW-CFP-TP

KNPC CLEAN FUELS PROJECT

Next revision "13"

PROJECT / CONTRACT REF.:

KNPC Clean Fuels Project

Training & Qualification Program for

4-Sep-16 12 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

1-May-16 11 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

18-Apr-16 10 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

9-Dec-15 9 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

16-Sep-15 8 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

9-Sep-15 7 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

30-Jul-15 6 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

7-May-15 5 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

21-Apr-15 4 ISSUED FOR REVIEW REMUS ORASA MARK BACUS

Training & Qualification Program for Adhesive

Project Client Doc. Title Doc. No.

KNPC – Clean Fuels Training & Qualification

D R A Date Printed: 4-Sep-16

Training & Qualification Program for Adhesive

The purpose of this training program is to obtain required skills to become a

1. ISO/FDIS 14692-4 (Petroleum and Natural Gas Industries – Glass Reinforced

3. Shell DEP 34.14.20.31 - Gen (Drainage Systems & Primary Treatment

4. VP-PV216A-109-A-000-P40-005 (Field Fabrication Procedure)

Project Client Doc. Title Doc. No.

KNPC – Clean Fuels Training & Qualification

D R A Date Printed: 4-Sep-16

Training & Qualification Program for Adhesive

The contractor crew, selected by the company/contractor from his workforce,

1. Proper Handling & Storage (Theory)

A course shall be conducted in proper handling and storage GRE materials

2. Tools, Raw Materials & Consumables (Theory)

Project Client Doc. Title Doc. No.

KNPC – Clean Fuels Training & Qualification

D R A Date Printed: 4-Sep-16

Training & Qualification Program for Adhesive

8 4” Angle grinder To be provided by JGSK

3. Reading & Comprehension (Theory)

A course shall be conducted in reading and comprehending the isometric

4. Fabrication and Jointing (Practical)

The joint making and testing should be witnessed by a recognized Accreditation /

KNPC – Clean Fuels Training & Qualification

D R A Date Printed: 4-Sep-16

Training & Qualification Program for Adhesive

Schedule : Day 2, 3, 4, 5 & 6

1. Fix the end closures to the test spool.

Schedule : Day 6 & 7

Project Client Doc. Title Doc. No.

KNPC – Clean Fuels Training & Qualification