MOS_GRP

TECHNICAL SUBMITTAL FOR THE INLET AIR

CHILLING FOR GAS TURBINES AT ‘L’ STATION,

PHASE 1, JEBEL ALI.

(SEA WATER & CHILLED WATER GRP PIPING)

PROJECT

:

CE/0081/2009

CLIENT

:

M/s. DEWA

FOREVER GENERAL CONTRACTING EST.

INDEX

1.

METHOD STATEMENT FOR THE INSTALLATION OF U/G GRP PIPES & FITTINGS

2.

SPECIFICATION FOR BUTT & STRAP JOINT FOR GRP PIPE AND FITTINGS

3.

PROCEDURE FOR JACKET PIPE LAMINATION

4.

GRP PIPING COMPONENTS DRAWING (PN 10)

5.

PRE INSULATED PIPE DRAWING – PN 16

6.

SPECIFICATION FOR RAW MATERIAL STORAGE

7.

GRP/GRV/GRE PIPE AND LAMINATION REPAIRING PROCEDURE

8.

PROCEDURE FOR HYDROSTATIC PRESSURE TEST AT SITE

9.

SAFETY PROCEUDRE

PROJECT

:

CE/0081/2009

CLIENT

:

M/s. DEWA

CONTRACTOR

: M/s.

APINA,

SPAIN

DOCUMENT NO.

:

MS/UG-Sp-001, REV. 0

FOREVER GENERAL CONTRACTING EST.

Page 2 of 7

Document no. MS/UG-Sp-001, Rev .0

TABLE OF CONTENTS

1.0 Introduction

2.0 Inspection of the pipe

3.0 Unloading & Handling of Pipes 4.0 Storage

4.1 Pipes Storage 5.0 Site Transportation

6.0 Trench Section and Terminology 7.0 Backfilling material

8.0 Recommendations for bedding and compaction 9.0 Lamination at Site

1.0 INTRODUCTION

This specification covers the requirements to achieve the proper installation of fibreglass piping systems in side DEWA Desalination and Power Station ‘L’ Phase 1(Project reference CE/0081/2009, Inlet Air Chilling for Gas Turbines).

2.0 INSPECTION OF THE PIPE

Pipe should be carefully inspected at the unloading site. Each consignment should be

visually checked to ensure that the pipes have not been mechanically damaged, externally or internally during handling.

- Internal Control (Look for White spots de-lamination) - External Visual Control (Look for damage due to shocks)

- Control of edges and Joints (Looks for de-lamination or chips due to shock)

A thorough inspection at this stage will avoid any unnecessary work resulting from installation of damaged materials.

3.0 UNLOADING & HANDLING OF PIPES

It is essential to maintain control of the pipe during unloading. Guide ropes attached to pipes or package will enable easy manual control when lifting and handling. It should get no shock and not be dropped. This applies especially to sleeves, retainer rings and ends of pipes. Always use pliable straps for lifting the pipe, never use steel cable or chain. Use only,

especially for big size pipes, only two support points (see sketch below). Fix both ends to keep control.

FOREVER GENERAL CONTRACTING EST.

Page 4 of 7

Document no. MS/UG-Sp-001, Rev .0 4.0 STORAGE

4.1 PIPES STORAGE

When storing the pipe on ground near the trench, it is necessary that the soil must be levelled and free of rocks and other potentially damaging debris. All the pipes should be choked to prevent rolling in high winds.

For long storage, pipe should be placed on supports with side blocks to prevent the pipe from rolling.

5.0 SITE TRANSPORTATION

Pipes can be easily transported. Their low weight and their high strength permit an easy and safe transportation. If pipes are transported by fork-lift, it is safe to put on the fork a chassis of 2 mt wide with wood pieces as support, to have more stability and avoid shock on the edges of pipes.

6.0 TRENCH SECTION AND TERMINOLOGY

Figure no. 2 illustrates the trench cross section to be used for underground pipes and terminology.

It is desirable to keep excavation, pipe installation and back fillings close together to minimise logistic problems and improve area accessibility.

Fig. 2 – Trench – Typical section for GRP Pipes

Where an unstable soil condition is encountered which is caused by a water table, the bottom of the trench must be stabilized before laying the pipes. This can usually be

accomplished by lowering the water table 120 cm below grade pipe by means of pumps and stabilizing the bottom as already described.

7.0 BACKFILLING MATERIAL

FOREVER GENERAL CONTRACTING EST.

Page 6 of 7

Document no. MS/UG-Sp-001, Rev .0

Fig. 3 - Type of Backfill Material for GRP Pipes

8.0 RECCOMENDATION FOR BEDDING AND COMPACTION

The bed must be over-excavated at each joint location to ensure that the pipe will have a continuous support. However, this area must be properly bedded and backfilled after the joint lamination is completed.

Compact by tamping. Tamping shall be done with:

- hand tampers for tamping under the haunches of the pipe;

- Mechanical tampers used over the entire area of each layer except the most confined zones;

- Tamping rollers, like rubber-tired or other types, used where space permits; - Vibrating compactors.

fig.4 : Proper Compaction under haunches

9.0 LAMINATION IN PREFABRICATION OR AT SITE

For Butt & Strap and branch Lamination at site, make reference to the specification ref: - MS/Lam-Sp-001, Rev.0 (Specification for Butt & Strap Joints for GRP Pipes and Fittings) 10.0 RIGID CONNECTIONS.

When a pipe passes through a concrete wall, a band of rubber has to be wrapped (200 mm wide and 10 mm thick) around the pipe in the area of entry into the concrete structure. In the case of watertight concrete structures a puddle flange shall be laminated on the portion of pipe inserted in the wall.

Furthermore it is necessary to achieve following conditions:

• Minimum depth of bedding has to be not less than one pipe diameter, but not to exceed the foundation depth of the concrete structure or 1 meter whichever is the lower, and for a length not less than two pipe diameters.

• Minimum width of trench has to be not less than three pipe diameters or 1 diameter + 2 meters, whichever is the lower, for a length not less than 3 pipe diameters.

FOREVER GENERAL CONTRACTING EST.

Page 1 of 8

Document no. MS/Lam-Sp-001, Rev .0

PROJECT

:

CE/0081/2009

CLIENT

:

M/s. DEWA

CONTRACTOR

: M/s.

APINA,

SPAIN

DOCUMENT NO.

:

MS/Lam-Sp-001, REV. 0

CONTENTS

1. INTRODUCTION ……….2

2. JOINING PROCEDURE……….….……2

3. JOINT LAMINATION………..……….…4

4. REQUIRED MATERIALS……….……5

5. PREPARATION OF RESIN………..………5

6. SAFETY PRECAUTION………..……….………6

7. FIRST AID……….……….6

FOREVER GENERAL CONTRACTING EST.

Page 3 of 8

1. INTRODUCTION

This Technical Specification describes the various phases of the manufacturing cycle for permanent

joints of pipeline elements in glass reinforced plastic (GRP), of plain end type, with reinforcement

wrapping obtained with lamination of mat and fiber glass impregnated with resin.

The ways to make butt & strap joints are two, depending on the pipe’s diameter and on the

possibility to access the inside of the pipe:

• Joint without putty and liner restoration from the outside up to the ND600

• Joint with putty and liner restoration from inside for diameters ≥ ND600

2. JOINING PROCEDURE

The manufacturing steps, needed to perform a joint, are shown in the following paragraphs.

2.1 CUTTING/ MARKING

Diamond tools (flexible discs) have to be used to cut and grind GRP pipes. Cardboard templates to

mark off oblique cuts for elbows or holes of branch connections are available on request. Special

equipment for cutting and beveling GRP pipes is available when the job extent requires it.

2.2 TAPERING

Depending on the diameter and on the type of joint, two kinds of tapering are available:

• long tapering, is for joint type without putty and with liner resetting from outside.

• short tapering (bevel) is for joint type with putty and internal liner resetting.

The two pipe ends to be connected must be handled in sequence as follows:

1. Clean thoroughly the two ends of the pipe for a length that must be slightly longer than the

length surface to be wrapped.

2. Grind all the surfaces to be laminated (external and eventually internal) with a pneumatic or

electric disc grinder, in order to create a rough area.

3. Taper the ends as required by the type of joint, using a grinder.

4. Blow air-jets to remove the dust.

5. Clean again and revive the resin with a suitable solvent (acetone).

6. Let it dry.

FOREVER GENERAL CONTRACTING EST.

Page 5 of 8

Document no. MS/Lam-Sp-001, Rev .0

2.4 ALIGNMENT

Align the two ends, leaving the required gap, from 3 to 10 mm, between the two plane faces to be

jointed.

2.5 LINER RESTORING

The restoration of the liner can be made from the inside of the pipe when the diameter is large

enough (ND

≥600mm) and when, apart from the size, it is possible to enter into the pipe.

It consists in the application of n.2 “C” glass surfacing veils, which must be in contact with the

liquid, and at least n.2 “E” glass mats (375 or 450 g/m²) resin impregnated:

A synthetic veil can be used instead of the “C” glass veil.

General Remark:

The lamination operations have to start at a time that allows to complete, before the night

suspension, at least the liner restoration and a lamination of 5mm thick for pipe diameters up to

800mm or 8 mm for larger diameters.

The temperature fall at night could cause thermal shrinkage of the parts and possible ruptures in

thin laminates.

¾ Liner Restoration From Outside.

When it is not possible to enter the pipe:

1. The two “C”glass veils and the two “E” glass mats will be applied on the external surface of the

ends to be connected, on the tapered area .The “C” glass surfacing veils and “E” glass mats will

be as wide as 100 mm.

2. If necessary clean and wash again with acetone the surfaces to be laminated.

3. As soon as the solvent evaporates, apply on the tapered area a first layer of resin and two layers

of C glass.

4. Repeat the operation with two layers of mat and resin, hence roll in order to eliminate bubbles

and defects of adhesion.

5. After the complete hardening, verify the absence of bubbles, delaminations or defects in the

jointing area.

eliminate air bubbles and to guarantee a correct impregnation.

7. Let polymerize completely (until cooling).

Note : Make sure that during the above operation the pipe ends are firmly fixed.

¾ Liner Restoration From Inside

In this case (joint with short taper), the taper must be filled with putty.

1. Check the alignment and the fixing of the pipe ends.

2. Prepare the putty according to the specific prescription.

3. Apply the putty with a putty knife, filling all of the voids.

4. After the filling of the taper, leave the putty to polymerize until cooling and according to the

specific requirements, without moving or hitting the pieces.

5. Once the hardening of the putty is completed, grind the putty drippings inside the pipe. Clean

with air blow and wash with acetone (If necessary).

6. Apply a first resin coat using a brush, on the internal surface to be laminated.

7. Apply two CSM “E” glass mat, resin impregnated and two “C” glass veils;

8. Apply with a brush the final coat of resin.

3.0 JOINT LAMINATION

a) Apply a first layer of resin, on the ground surface.

b) Apply a strip of "E" glass, and impregnate it with resin.

c) Eliminate air bubbles with a bubble breaker roll.

d) Apply a strip of glass mat cut to measure, and impregnate it with resin.

e) Eliminate air bubbles with a bubble breaker roll.

The above operations (b-e) will be performed and repeated until the total required thickness is

reached. If the total thickness to be reached is very high, it is necessary to perform several layers of

a reduced thickness and wait for the hardening of the resin between a layer and the following one.

Notice: every single layer must finish with a layer of "E" glass mat.

After that the required thickness is achieved and that the hardening is completed, apply with a

brush a coat of resin on the external surface of the joint.

FOREVER GENERAL CONTRACTING EST.

Page 7 of 8

Document no. MS/Lam-Sp-001, Rev .0

3.1 EXECUTION WITH EXTERNAL LINER RESTORATION

Since it is not possible to work inside the pipe, the bevel will be on the outer part and with a long

tapering.

Two “C” glass veil and two CSM 375 “E” glass mats will be applied on the tapered surfaces.

In order to increase the bending radius of the successive laminations, apply over the liner

restoration some putty or “E” glass mat strips impregnated of resin.

3.2 EXECUTION WITH INTERNAL LINER RESTORATION

The bevel is made in the inside part of both the main and the branch. The bevel will be filled with

putty.

The internal reinforcement must terminate with two “E’ Glass mats and two “C” glass veils in

contact with the medium. (Internal Liner restoration)

For the lamination of the internal and external lamination follow the section 2.6.

4.0 REQUIRED MATERIALS

The following materials are necessary:

ƒ Thermosetting resin.

ƒ Catalyst, accelerators and different additives.

ƒ “C” glass stripes, mat and woven roving.

ƒ Acetone / Similar solvent.

ƒ Putty and relative catalysts, accelerators and different additives, when required.

5.0 PREPARATION OF RESINS

The types of resin, catalysts, accelerators and additives are indicated in the specific instructions for

each project or job.

The putty is a resin with thixotropic additives.

• Pour the necessary quantity of resin or putty into a container.

• Add the necessary quantity of accelerator (unless it is already accelerated)

• Mix thoroughly the accelerator with resin.

• Add required quantity of catalyst.

At this point the resin is ready to be applied. It takes from 10 to 30 minute before the hardening

begins.

Warning: - Never mix the accelerator and the catalyst directly. Explosions may occur or also

highly oxidizing phenomena.

6.0 SAFETY PRECAUTIONS

• Do not seal the catalyzed resin tanks.

• Do not smoke or use free flames anywhere close the jointing areas, under any

circumstances.

• Safety glasses must be worn while grinding and mixing the resin.

• Tools must be kept clean by washing them in acetone or in similar solvent.

• Protective gloves should be used to handle the resins and resin impregnated glass fibers.

• Closed areas, such as the inside the pipe, or protected areas should be ventilated to avoid

an excessive inhalation of resin vapors, and in order to eliminate the possibility of fire by

combustible gas.

7.0 FIRST AID

Some procedures of first aid are listed below.

a) Contact with eyes. Wash with plenty of water and call for medical aid.

b) Contact with skin. Wash with water and soap.

c) Excessive inhalation of vapour. Go out in the open air.

d) Ingestion. Induce vomiting and call for medical aid.

In case of fire use CO2, foam or powder extinguishers must be with in reach in the working area in

every moment.

DOC NO. : FGC/J/LM-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 15/12/2010

ESTABLISHMENT

PAGE : 1 OF 3

PROCEDURE FOR JACKET PIPE

LAMINATION

PAGE : 2 OF 3

Scope:

This procedure describes the method for jacket pipe lamination

Jacket Pipe Lamination Procedure

After the successful hydro testing of core pipeline, the core pipe lamination joints are covered with jacket sleeves by lamination as per the procedure described below;

1) Cut the Jacket sleeves symmetrically into two halves. 2) Grind and chamfer the jacket sleeves at width of

lamination required.

3) Clean the core pipe lamination joint area and jacket sleeve with acetone.

4) Assemble the jacket sleeve on the core pipe lamination joint, in such a way that the gap between the joints should be in the range of 3-6 mm

5) After proper positioning of the jacket sleeve, the gap is filled up with Isophthalic resin putty.

6) Allow the Isophthalic resin putty to cure. After curing, grind the surface and clean with acetone and allow it to dry.

7) The external lamination should start immediately by applying a coat of activated Isophthalic resin.

8) Apply 1 layer of C-Veil cut to measure and impregnate with activated resin.

9) Apply 2 layer of CSM cut to measure and impregnate with activated resin.

10) Eliminate air bubbles with a bubble breaker roller. 11) Apply one layer of Woven Roving, cut to measure,

and impregnate with activated resin.

12) Eliminated bubbles with a bubble breaker roller.

13) Continue steps with alternated layers of CSM and Woven Roving till the required thickness of lamination is achieved.

DOC NO. : FGC/J/LM-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 15/12/2010

ESTABLISHMENT

PAGE : 3 OF 3

Tools Required For Lamination

1) Grinders, Rollers, Scraper, Generator, 2) Jug, Mug, Measuring Jar, Bucket

Materials For Lamination

1) Isophthalic Resin 2) Hardener

3) Acetone (for cleaning) 4) Iso putty

5) C-glass Veil

6) Woven Roving (WR) 400 g/m²

7) Chopped Strand Mat (CSM) 300 g/m²

Dimensional Table - 1

Diameter (mm) Lamination Thickness (mm) Lamination Width (mm)

991.5 6.0 400

Curing Time

24 Hours.

Protection Of Work

1) All lamination work shall be made under protection from direct sunlight.

2) FGC will not proceed with the lamination works in case of any sand storm, rain or during a condition of excess humidity where people are not able to work comfortably and may create heat strain or sun stroke.

Tests And Examinations

Barcol Hardness check and dimension check.

Acceptance Criteria

Barcol Hardness should Minimum 35. Dimensional inspection will be accordance with dimensional table 1.

JOB: CE/0081/2009

CLIENT: M/s. DEWA

PROJECT: JEBEL ALI "L" STATION PHASE I Gas Turbine Inlet Air Chilling Project

GRP PIPING COMPONENTS DRAWINGS

DESIGN PRESSURE: 10 bar

RESIN: VINYLESTER RESIN

ISOPHTHALIC WALL

18/12/2010 0 ISSUED FOR CONSTRUCTION ZA NAS NAS

DATE Rev. N° DESCRIPTION Written Checked Approved

PIPE JOB: CE/0081/2009

PLAIN ENDS DOC: FGC-DD-002 REV.: 0 Date:

Forever General Contracting

From to 25 3000 3.5 4.5 0.8 150 9000 4 5.0 2.8 250 9000 4.2 5.2 7.0 500 12000 7.5 8.5 24.5 700 12000 10 11.0 46.5 1000 12000 13.9 14.9 60.2 CONSTRUCTION: TOLERANCES:

- Liner: - "C" glass surfacing veil 1.5 mm - "E" glass Mat

-Struct. Wall: - F.W. with "E" glass continuos roving

Isophthalic Reisn L: +50/-100 mm

-Top coat

- Resin : Vinylester Liner

NOTE:- Dimensions in mm, Weight in Kg/m

18/12/2010 CLASS - PN 10 Declared Stiffness : 5000 N/m² t DN L w Vinylester Rein t ND L

ND L t w

150 225 4.0 1.5

250 375 5.8 5.4

CONSTRUCTION: TOLERANCES:

-Liner - "C" glass surfacing veil

- "E" glass Mat 1.5 mm - t: -0 +20%

Vinylester Resin

- Struct. wall - Alternate layers of "E" glass - R: +/- 5%

Mat and woven roving Isophthalic Resin - Top coat

- Resin : Vinylester Liner

NOTE: - Dimensions in mm, Weight in kg.

ND

L

L

90°

R=1.5ND

ELBOW 45° JOB: CE/0081/2009 DOC: FGC-DD-002

PLAIN ENDS REV.: 0 Date:

Forever General Contracting

ND L t w

150 93 4.0 0.8

CONSTRUCTION: TOLERANCES:

-Liner - "C" glass surfacing veil

- "E" glass Mat 1.5 mm - t: -0 +20%

Vinylester Resin

- Struct. wall - Alternate layers of "E" glass - R: +/- 5%

Mat and woven roving Isophthalic Resin - Top coat

- Resin : Vinylester Resin

NOTE: - Dimensions in mm, Weight in kg.

18/12/2010 CLASS - PN 10

L

R=1.5ND

t

ND

L

45°

ND a t b s [mm] [mm] [mm] [mm] [mm] 500 200.0 13.0 N/A N/A 700 250.0 15.0 75.0 3.0 1000 350.0 22.0 75.0 4.0 TOLERANCES: - t: -0 +20% - R: +/- 5%

- Resin : Isophthalic wall / Vinylester Liner

NOTE: - Dimensions in mm, Weight in kg.

CONC./ECC. REDUCER JOB: CE/0081/2009 DOC: FGC-DD-002

PLAIN ENDS REV.: 0

Date 00/01/1900

Forever General Contracting Est.

ND1 ND2 L t w

500 350 375 11.0 6.8

150 100 125 5.0 0.5

CONSTRUCTION: TOLERANCES:

-Liner - "C" glass surfacing veil

- "E" glass Mat 1.5 mm - t: -0 +20% Vinylester Resin

- Struct. wall - Alternate layers of "E" glass - L: +/- 5 mm Mat and woven roving

Isophthalic Resin - Top coat

- Resin : Vinylester resin NOTE: - Dimensions in mm, Weight in kg.

CONCENTRIC REDUCER CLASS - PN 10 ND1 ND2 L t 1 of 1

ND min L tf ef mf Df w DRILL 25 110 20 81 49 108 0.4 ANSI B 16.5 150# 40 120 21 85 66 127 0.7 ANSI B 16.5 150# 50 120 22 88 85 152 1.0 ANSI B 16.5 150# 100 140 26 104 144 228 2.0 ANSI B 16.5 150# 150 200 30 120 196.0 279.0 3.6 ANSI B 16.5 150# 250 270 31 124 296.0 406.0 6.3 ANSI B 16.5 150# 500 480 45 180 556.7 699.0 18.2 ANSI B 16.5 150# 700 620 58 232 773.0 927.0 38.0 AWWA C 207D 900 800 67 268 987.0 1168.0 65.0 AWWA C 207D CONSTRUCTION: TOLERANCES:

- Liner - "C" glass surfacing veil 1,5 mm

- "E" glass Mat tf, mf, ef: - 0/+10% Vinylester Resin L: +10/-5 - Struct. wall - Alternate layers of "E"

Mat and woven roving Isophthalic Resin - Top coat

Vinylester Resin

- Bolt torque and bolting sequence to be in accordance with ASTM D4024 - Gasket: -flat

BLIND FLANGE JOB: CE/0081/2009 DOC: FGC-DD-002

REV.: 0

Date:

Forever General Contracting Est.

ND tf Df w DRILL

900 95 1168 172 AWWA C 207D

CONSTRUCTION: TOLERANCES:

- Liner - "C" glass surfacing veil 1,5 mm

- "E" glass Mat tf: - 0/+20% Vinylester Resin

- Struct. wall - Alternate layers of "E" Mat and woven roving Isophthalic Resin - Top coat

- Resin : Vinylester Resin

- Bolt torque and bolting sequence to be in accordance with ASTM D4024

NOTE:- Dimensions in mm, Weight in kg.

CLASS - PN 10 18/12/2010

tf

Df

ND L t w 150 126 4.6 0.3 250 176 7.4 1.7 500 350 12.7 11.6 1000 550 20.0 82.0 CONSTRUCTION: TOLERANCES:

- Liner - "C" glass surfacing veil 1.5 mm

- "E" glass Mat tf: - 0/+20% Vinylester Resin

- Struct. wall - Alternate layers of "E" Mat and woven roving Isophthalic Resin - Top coat

- Resin : Vinylester Resin

NOTE:- Dimensions in mm, Weight in kg.

L

ND

BUTT & STRAP JOINT JOB: CE/0081/2009 DOC. FGC - DD-002 REV.: 0 Date: 18/12/2010

Lamination without putty <=ND600

ND te Le ti Li w 25 3 100 N/A N/A 0.04 40 3 100 N/A N/A 0.07 50 3 100 N/A N/A 0.08 80 3 100 N/A N/A 0.12 100 4 100 N/A N/A 0.20 150 5 130 N/A N/A 0.30 250 7 200 N/A N/A 1.40 500 13 400 N/A N/A 11.80 700 15 500 3 150 25.00 900 20 600 4 150 63.00 1000 22 700 4 150 71.00

- Struct. wall - Alternate layers of "E" glass te

Mat and woven roving /Combi Mat L: + 10/ - 5 % Isophthalic Resin

- Top coat Vinylester Resin

NOTE: - Dimensions in mm, Weight in kg.

CLASS - PN 10

Lamination with putty >ND600 Forever General Contracting

ND ND2 t s a d b L q c W (Kg*) 900 20 22 300 300 120 1,521.00 4 200 216 700 18 19 250 250 100 1,218.00 4 170 149 500 18 19 200 200 80 914.00 3 100 104 900 700 17 18 250 250 100 1,218.00 4 140 130 500 250 10 10 110 110 80 480.00 N/A N/A 16.0 250 150 5 6 100 100 80 358.00 N/A N/A 3.5 150 150 4 4 100 100 80 318.00 N/A N/A 1.4 150 100 3 4 80 80 50 268.00 N/A N/A 0.9 150 80 3 3 80 80 50 247.00 N/A N/A 0.7

- Struct. wall - Alternate layers of "E" glass te

Mat and woven roving /Combi Mat L: + 10/ - 5 % Isophthalic Resin

- Top coat Vinylester Resin

NOTE: - Dimensions in mm, Weight in kg.

1000 t s a b b d L c q _D1 D2

JOB: CE/0081/2009 DOC. FGC - DD-002 REV.: 0 Date: 18/12/2010 ND ND2 t s a d b L q c W (Kg*) 250 15 16 220 220 80 700.00 2 100 22 150 13 15 180 180 80 518.00 2 100 9 50 10 11 120 120 80 297.00 N/A N/A 2.3 40 10 11 110 110 80 267.00 N/A N/A 1.9 25 9 9 100 100 80 231.00 N/A N/A 1.4 50 10 11 120 120 80 297.00 N/A N/A 2.3 40 9 10 110 110 80 267.00 N/A N/A 1.8 25 8 9 100 100 80 231.00 N/A N/A 1.3 50 8 9 100 100 80 257.00 N/A N/A 1.5 40 8 8 100 100 80 247.00 N/A N/A 1.2 25 7 7 100 100 80 231.00 N/A N/A 0.9 50 6 7 100 100 80 257.00 N/A N/A 0.7 40 6 7 100 100 80 247.00 N/A N/A 0.5 25 5 6 100 100 80 231.00 N/A N/A 0.4

- Struct. wall - Alternate layers of "E" glass te

Mat and woven roving /Combi Mat L: + 10/ - 5 % Isophthalic Resin

- Top coat Vinylester Resin

NOTE: - Dimensions in mm, Weight in kg.

500

RED. TEE (BRANCH JOINT)

LOCAL REINFORCEMENT PLAIN ENDS

CLASS - PN 10 Forever General Contracting

1000 700 900 t s a b b d c q D1 D2

PAGE : 1 OF 2

SPECIFICATION FOR RAW

MATERIAL STORAGE

DOC NO. : FGC/RM-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 12/01/2010

ESTABLISHMENT

PAGE : 2 OF 2

Scope:

This specification briefly describes about the storage of GRP/GRV/GRE raw materials.

Procedure

Resin and Additives:-

Resin and other chemicals shall be stored in the original drums and other packages, indoors, in dry, dark and ventilated ambient at a temperature of approximate 25° C. In this case the average life is 6 months.

The standard life of resin and additives will be shortened and will be as lower as the room temperature is higher.

The lower temperature (<25° C) will cause the crystallization of resin. Then the resin will look milky and thickened. But with no deterioration or reduction in life. Heat up to 40-50° C and stir thoroughly before use.

Glass Fibers:-

Glass fibers shall be stored indoor and left sealed inside the original envelop in order to be protected from humidity. But they are not temperature sensitive. Stored in these conditions the fiber glass has an unlimited life.

Note:

1) Both drums and packages shall not be opened if the product is not used within short time.

2) The raw liquid materials are flammable and shall be stored far from naked flames or source of heat.

3) Apart from such risks, incorrect storage shall be reduce their working life to less than 6 months (which is their standard level of duration)

PAGE : 1 OF 3

GRP/GRV/GRE PIPE AND

LAMINATION REPAIRING

PROCEDURE

DOC NO. : FGC/RP-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 12/01/2010

ESTABLISHMENT

PAGE : 2 OF 3

1.0 Scope:

This procedure describes the repairing of GRP Pipes and Lamination defects. 2.0 Tools Required: 1) Electric Grinder 2) Diamond Disc 3) Emery Disc 4) Hard Roller 5) Soft Roller 3.0 Procedure:

Sl No. Defects Method of Repair

1 Air Bubble & Blister

Acceptable level for Air Bubble (Maximum diameter 1.5 mm Above 1.5 mm repair) Acceptable level for Blisters (Maximum diameter 3 mm Above 3 mm repair)

1) Grinding with emery disc 2) Clean the grinded surface 3) Apply a layer of activated Resin 4) Apply one C-Veil and apply resin 5) Roll with hard roller to remove the air

thoroughly.

2 Crazing & Wrinkles

Acceptable level Maximum dimension 13 mm

Above 13 mm repair as

1) Grind the crazed /wrinkled area 2) Clean the grinded surface 3) Apply a layer of Activated resin 4) Apply one layer of CSM

5) Apply the roller.

6) Put one layer of C veil for finishing. 7) Apply the hard roller for finishing.

PAGE : 3 OF 3

3 Delamination & Foreign inclusion

Acceptable level None Repair as

1) Grind the crazed /wrinkled area 2) Clean the grinded surface 3) Apply a layer of Activated resin 4) Apply one layer of CSM

5) Apply the roller

6) Put one layer of C veil for finishing 7) Apply the hard roller for finishing.

4 Pinholes

Acceptable Level Maximum diameter 0.4 mm

Above 0.4 mm repair as

1) Grinding with emery disc 2) Clean the grinded surface 3) Apply a layer of activated Resin 4) Apply one C-Veil and apply resin 5) Roll with hard roller to remove the air

thoroughly.

5 Surface Scratches

Acceptable level : Maximum deep 0.2 mm Above 0.2 mm repair as

1) Grinding with emery disc 2) Clean the grinded surface 3) Apply a layer of activated Resin 4) Apply one C-Veil and apply resin 5) Roll with hard roller to remove the air

DOC NO. : FGC/HT-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 12/01/2010

ESTABLISHMENT

PAGE : 1 OF 4

PROCEDURE FOR HYDROSTATIC

PRESSURE TEST AT SITE

PAGE : 2 OF 4

1.0 Scope:

This Specification guides the proper Hydro static pressure testing of GRP underground and above ground piping system.

2.0 Principle:

2.1 For underground piping system, testing is preferably carried out after complete backfilling of the pipes except joint. The joints should be kept without backfilling in order to detect the leak.

2.2 The proposed limits for the hydrostatic test of GRP Pipelines are generally flanges, unless otherwise indicated in the drawings or instructed by the Clients.

2.3 The line ends will be closed by using temporary or permanent blind flanges.

3.0 Equipment Required For Testing:

3.1 One Set of Blind flanges (GRP/Steel), with nuts, bolts, washer and gaskets.

3.2 One Head (Blind Flange) with Ø 50 mm Flange for Water Filling and Ø 25 mm Adaptor for Pressurizing.

3.2 Pressure Pump.

3.2 Water Pump (if Required). 3.3 Filling Hose and Water tank.

3.4 Tool Box

3.5 Calibrated Pressure Gauge (2 Nos.) 4.0 Testing Procedure:

Prior to preparation for testing, it is to be ensured that,

a) The solid wastes like wooden pieces, raw material waste etc shall be removed from inside of the pipeline.

b) Test pack is prepared for the section to be tested.

c) Punch list is prepared listing out all the outstanding activities for the section to be signed by all concerned.

d) Section is released for hydro test and signed by all concerned. 4.1 Line Check up

DOC NO. : FGC/HT-001

REVISION : 0

FOREVER GENERAL CONTRACTING

DATE : 12/01/2010

ESTABLISHMENT

PAGE : 3 OF 4

4.1.2 All joints should be exposed and should be dry to carry out inspection.

4.1.3 The inside of the pipeline should be free from solid wastes. 4.1.4 If the partial back filling is not done, sufficient load should be provided above and sides of the pipe for restricting the vertical and lateral movement during pressure test. Ensure the load to be distributive and not point load.

4.2 Installation of Test Plugs.

4.2.1 Install blind flanges/ End caps.

4.2.2 If end caps are using then laminate the caps to the pipes properly.

4.2.3 Blind flanges to be tightened with proper torque. 4.3 Filling of Line

4.3.1 Filling has to be made at the lowest point of the line. Air will be removed from the other pressure head at the highest point. Fresh Water to be used for testing.

4.3.2 As soon as water comes out from the air release port at the other side of the pipe line, close them slowly. Ensure that complete entrapped air is removed through the air release port.

4.3.3 Connect the pressure gauges (2 Nos.) at both ends.

4.3.4 Range of pressure gauge should be within 1.5 to 4 ties of the testing pressure.

4.4 Pressurizing

4.4.1 The pipeline can now be pressurized by pump capable of pressurizing the system up to the required test pressure at a pre-set rate.

4.4.2 The increase in pressure shall not be larger than 1 bar every 10 minutes for diameters larger than 500 mm and 1 bar every 5 minute for lower /equal diameters.

4.4.3 The pressure testing shall not be done when the water temperature is less than 5° C.

PAGE : 4 OF 4

4.4.4 During initial pressurization, the cross sectional area of the pipe will increase owing to the elastic modulus of the material and thus there will be a slight increase in volume and drop in pressure. 4.4.5 Increase the pressure gradually up to the working pressure in stages, allowing time in between, for the pressure to stabilize. The same shall be maintained for a minimum duration of one hour in order to allow the complete mechanical & Thermal equilibrium of pipeline.

4.4.6 Increase the pressure of the pipeline up to the test pressure which shall be 1.5 times the working pressure.

4.4.7 The test pressure should be held for a period of 2 hours (minimum) or a period sufficient to enable visual inspection of all pipe joints. All visible joints should be inspected for the leaks and the test result should be recorded.

4.4.8 Release of pressure should be also in stages allowing 15 to 20 minutes at each stage for pressure to stabilize.

The pipeline is acceptable if no leaks are found in the joints as well as in the pipes. If any leak found drain the line and rectify the joint. After completing the rectification redo the test.

Doc. No : FGC-HSE-01

Revision : 0

Date : 15/05/2010

SAFETY PROCEDURE

Page : 1 of 7

Revision Date Nature of Changes

0 15/05/2010 Initial Preparation & Approval

1.0 PURPOSE

The purpose of this procedure to help the site management team to establish / implement the HSE standards in compliance with local legislations, good practices and company standards.

2.0 SCOPE

This procedure details the necessary information and action for Health, Safety & Environment for our site. The overall aim is to;

1) Manage the risk.

2) Minimize the effect of consequences.

3) Protect the employees and others who may be affected by our Site activities from the risk to their health and safety.

3.0 DEFINITIONS

1) FGC – Forever General Contracting Est. 2) COMPANY- Forever General Contracting Est. 3) HSE-Health Safety & Environment.

4.0 RESPONSIBILITIES

HSE Officer is responsible to provide necessary training to all employees and to ensure & monitor the effective implementation of this procedure and to take necessary actions when required. Also, HSE Officer is responsible to maintain & update the validity of the safety certifications of the equipments.

All Site Supervisors are responsible for; 1) Provision of a safe work place.

2) Provision of work equipments that is safe.

3) Provision of sufficient emergency arrangements. (Fire, first aid etc.)

4) Provision sufficient and suitable safety measures including personal protective equipments.

All employees are fully responsible; 1) To follow this safety procedure.

2) To bring the attention of management reporting dangerous situations

3) A duty of care to themselves and others who may be affected by their acts or omissions

4) To performing their work in a safe manner. If they are unsure of the safe way to proceed, they should ask for assistance from their supervisors. 5.0 REFERENCE

This procedure has been prepared following the guidelines as stipulated in below given ref. standards / local regulations.

¾ Dubai Code of Construction

¾ CIP Construction Health and Safety Manual

¾ OSHA Workplace Requirement for Safety and Health

¾ CITB Construction Site Safety Course

¾ IOSH Principle of Health and Safety at Work

¾ Local Order 61/1991

Doc. No : FGC-HSE-01

Revision : 0

Date : 15/05/2010

SAFETY PROCEDURE

Page : 3 of 7

6.1 General Safety Precautions

6.1.1. HEALTH, SAFETY AND ENVIRONMENT

The Forever General Contracting Establishment will conduct its operations in such a manner as to:

Provide a safe working environment;

Ensure the safety and health of Company and employees within all areas of the Company's operations;

Provide information to employees regarding the hazards and risk involving company's operation.

Protect the workers from injury or ill health;

Provide and maintain adequate welfare facilities to employees; Prevent the loss or damage to the property;

Safeguard the natural environment;

Treat safety in the same way as all other primary business objectives.

6.1.2. REPORTING OF EMERGENCIES

Any person involved in or witnessing an emergency at FGC site, should take the following actions:

Contact the local Control Room, on the emergency telephone number, give the operator concise information such as:

Your name, location and telephone number. Location of incident.

Type of incident, e.g. fire, vehicle collision etc.

Incident status, e.g. fire extinguished or not, minor / major etc. Personnel injuries, and if medical assistance is required.

Any other information which will help safeguard personnel and equipment.

In the event of a fire, attempt to extinguish where possible BUT TAKE NO RISKS. 6.1.3. BASIC SAFETY RULES

Smoking is prohibited in all hazardous and flammable areas especially inside the chemical storage area and lamination site.

Personnel protective equipment must be worn by all employees as stipulated by the FGC Supervisor.

All tools and equipment must be inspected and tested for safety before being put to use. Any crane, hoist or lifting machine that is to be brought into FGC site must have a copy of its current inspection certificate with it.

All employees working for FGC inside any plant or factory shall be familiar with the emergency procedures (location of the nearest fire alarm, the escape routes and the correct extinguishers and their location.)

No guards or protective devices may be removed or misused by employees from any machine, or other facility.

When using welding equipment, fireproof screens must be used to protect employees from welding flashes.

All employees, if involved in or witnessing an accident (such as injury, vehicle collision, fire, property damage, atmospheric pollution etc. or near miss) shall inform the FGC Supervisor and the Control Room Immediately.

6.1.4 ACCIDENT PREVENTION

If in doubt about the safest way to do a job, seek guidance from your Supervisor. Be on the look out for hazardous situations.

Report all defects you are not able to rectify yourself. Report them to your Supervisor. If no action follows, raise it again with your supervisor and ensure that it is discussed at the next management review meeting.

Report all near misses, accidents and injuries. By reporting these you may well prevent someone suffering a misfortune.

Doc. No : FGC-HSE-01

Revision : 0

Date : 15/05/2010

SAFETY PROCEDURE

Page : 5 of 7

6.1.5 PERSONAL PROTECTIVE EQUIPMENT (PPE) Hand Protection

In our daily work situation there are many occasions when our hands need some protection from chemicals, sharp objects, dirt, and rough or abrasive surfaces. Appropriate types of gloves should be used in such work situations.

Foot Protection

Safety foot wear is mandatory when working at FGC sites. Body Protection

Coveralls provide good protection against certain hazards and dirt. Employees are not allowed to carry out the work without wearing coveralls. All coveralls shall be of 100% cotton materials.

Eye Protection

Eyes are liable to damage from resin, catalysts, accelerator, excess lights and heat etc. Care should be taken while mixing, handling or using these chemicals.

6.1.6 CRANES AND OTHER LIFTING MACHINES

Never attempt to operate a crane, forklift or other types of lifting machines unless you have written authority to do so.

Walk around your machine before starting it, to check for defects and obstruction. Report any defects in you machinery to our supervisor.

Make sure that you know the safe working Load of your machine and the weight of any load you are required to lift. Try the load by lifting it slightly and halting, to see if the machine can take the load.

Never stand under a load while it is suspended. 6.1.7 DANGEROUS MACHINERY

Power driven grinding and cutting tools are obviously dangerous items of machinery. 6.1.8 HAND AND POWER TOOLS

All electrical power tools to be of approved recognized standard and double insulated. Never use tools which are in any way defective.

Inspect tools, cables and connections regularly and take defective items out of use and ensure that all guard is in position.

Make sure that handles are securely fitted to files, screwdrivers, hammers etc. Keep tools clean and put them away after use.

6.1.9 FIRE PREVENTION

Look out for sparks and hot slag falling from welding, cutting and other hot work. Report all fire hazards.

Do not place flammable liquid containers near sources of heat. Obey any no smoking signs or instructions.

If you find a fire, raise the alarm immediately. Only attempt to fight the fire if it is safe to do so.

Identify the position of fire extinguishers and other fire-fighting equipment. 6.2 Safety Precautions for Chemical used

1) Resins.

2) Additives.

6.2.1 RESIN

It is recommended that eye protection & other protective clothing to be worm when handling or using resins.

When cleaning up spillage's it is advisable that respiratory protection is also worm. Contaminated Clothing should be removed immediately and wasted before re-use.

Splashes to the skin should be wiped clean and the affected area to be washed clean with soap and water.

Splashed in the eyes should be treated immediately by flushing with large amount of clean water for at least 15 minutes, followed by medical attention.

If resin is accidentally ingested 2 or 3 glasses of water or milk should be given and medicate assistance obtained.

Doc. No : FGC-HSE-01

Revision : 0

Date : 15/05/2010

SAFETY PROCEDURE

Page : 7 of 7

Peroxides are flammable, keep away from sources of ignition and heat.

Store peroxides in a cool dark place - well separated from accelerators and other flammable material.

Observe exact storage temperature indicated on product label.

DANGER OF EXPLOSION: Never mix. Peroxides and accelerators together, add each component separately to the resin.

Store peroxides in original containers contact with rust, ash, dirt, accelerators and many chemicals can cause violent decomposition

Even in diluted form peroxides have a corrosive effect on the skin and eyes. Always wear gloves and protective goggles when handling peroxides.

In case of eye contact with the Additives, rinse immediately with large quantity of water for at least 10 - 15 minutes, contact the doctor immediately.

In case of accidental swallowing of additives administer water in small sips and charcoal tablets in addition, call a doctor immediately.

In case of contact with skin or body, Remove socked clothed immediately. Wash skin with plenty of water & cover skin with sterilized bandages.

In case of small fires, suitable extinguishers are water spray & foam.

In case of large fires, fight fire from safe distance 10 - 15 mts, call a fire brigade immediately.

Acetone should never be used as diluents for methyl ethyl ketone peroxide, which reacts with acetone forming acetone peroxide crystals which are extremely shock sensitive. Use only inert diluents.

7.0 RECORDS

1) Safety Induction Training Record 2) Tool Box Talk Record

3) Crane Inspection Report 4) Generator Inspection Report

PROJECT

INSPECTION & TEST PLAN

GRP PIPES - PN 10 & PN 16

DOC' NUMBER 0081/2009-ITP-001 REVISION 0 DATE 19/12/2010

ITEM I COMPONENT Sea Water Line & Pre Insulated Pipes - GRP PIPES Class - PN 10& PN 16 SHOPISITE SITE PROJECT Inlet Air Chilling for Gas Turbines at "L" Station, Ph.1 Jebel Ali

EMPLOYER NAME DUBAI ELECTRICITY AND WATER AUTHORITY CONTRACTOR MIs. Apina Middle East

SUBCONTRACTOR Forever General Contracting Est.

PREPARED BY ZA APPROVED BY

LEGEND OF ACTIVITY ABBREVIATIONS

H· HOLD (MANDATORY HOLD POINT UNTIL INSPECTION COMPLETE) R • REVIEW (RECORD I REPORT REVIEW)

S • SURVEILLANCE INSPECTION (RANDOM CHECK)

W • WITNESS INSPECTION POINT (PROCEED IF INSPECTION AUTHORITY NOT AVAILABLE)

NOTES CLIENT REVIEW APPROVALS

1.ALL INTERNAL CONTROL DOCUMENTS SHALL BE THE LATEST REVISION.

2.CONSTRUCTION MATERIALS MUST BE APPROVED PRIOR TO START ANY WORK.

DOC : CE/0081/2009 REV : 0

REFERENCE

DOCUMENTS ACCEPTANCE CRITERIA

DOCUMENTATION QUALITY

REPORT REQUIRED APINA

1.0 RAW MATERIAL INSPECTION

1.1 RAW MATERIAL SUPPLIER

DATA SHEET

DATE OF EXPIRE/ REACTIVITY

TEST N/A S

1.2 RAW MATERIAL SUPPLIER

DATA SHEET N/A N/A S

,2.0 GRP COMPONENT INSPECTION(PIPES,FITTINGS AND SPOOLS)

2.1 FGC GRP Piping Component Drawing FGC-DD-002 FGC GRP Piping Component Drawing FGC-DD-002+Isometric Drawings) N/A S 2.2

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0 N/A 3.0 TRACEABILITY 3.1 CERTIFICATE OF CONFORMITY FROM SUPPLIER

RAW MATERIAL DATA SHEET N/A R

3.2

CERTIFICATE OF CONFORMITY FROM

SUPPLIER

RAW MATERIAL DATA SHEET N/A R

4.0 GRP LAMINATION

4.1

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

N/A S

4.2

SPECIFICATION FOR BUTT & STRAP JOINTS FOR GRP PIPES AND FITTINGS and GRP Piping Component

Drawing FGC-DD-002

SPECIFICATION FOR BUTT & STRAP JOINTS FOR GRP PIPES

AND FITTINGS and GRP Piping Component Drawing FGC-DD-002 LAMINATION INSPECTION REPORT(0081/09/LR-01 & 0081/09/BLR-02) W DEWA S S S R R S S

PREPERATION ASSEMBLING,GRINDING AND

LAMINATION(FIELD LAMINATION) H S

CHECKING HANDLING OF COMPONENTS H

RAW MATERIAL R

DIMENTIONAL CONTROL

CHECK FOR COMPONENTS DAMAGES BEFORE INSTALLATION

H

H

Inlet Air Chilling for Gas Turbines at "L" Station Phase I, Jebel Ali

CHECKING OF GLASS FIBERS ASPECT

CHECKING OF RESIN AND ADITIVES W

FGC

SITE INSPECTION AND TEST PLAN

PROJECT NO:CE/0081/2009

R

COMPONENTS R

REFERENCE

DOCUMENTS ACCEPTANCE CRITERIA

DOCUMENTATION QUALITY

REPORT REQUIRED FGC APINA DEWA

4.3

SPECIFICATION FOR BUTT & STRAP JOINTS FOR GRP PIPES AND FITTINGS and GRP Piping Component

Drawing FGC-DD-002

SPECIFICATION FOR BUTT & STRAP JOINTS FOR GRP PIPES

AND FITTINGS and GRP Piping Component Drawing FGC-DD-002 LAMINATION INSPECTION REPORT(0081/09/LR-01 & 0081/09/BLR-02) W

4.4 ASTM D 2583 BARCOL TEST VALUE

GREATER OR EQUL To 36

LAMINATION INSPECTION REPORT(0081/09/LR-01 &

0081/09/BLR-02)

W

5.0 GRP UNDER GROUND INSTALLATION

5.1

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

CIVIL COTRACTOR SURVEY REPORT(HANDING OVER

FOR BENIFICIAL OCCUPATION)

R

5.2

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

Method statement for the installation of GRP Under ground pipes & Fittings - MS/UG-Sp-001, Rev .0

HANDING OVER FOR BENIFICIAL OCCUPATION

REPORT(0081/09-IR-01)

S

5.3

Procedure for hydrostatic pressure test at site

(FGC/HT-001)

No leakge or Pressure Drop Hydro static test Report S

S

R R S

R WORKSHOP AND FIELD LAMINATION JOINT VISUAL

INSPECTION AND DIMENTIONAL CONTROL H

BARCOL HARDNESS TEST OF LAMINATION H

H HYDRO TEST

CHECKING OF BEDDING H