OMIFCOOMIFCOSUR – SULTANATE OF SUR – SULTANATE OF

OMANOMAN

OMAN-INDIA FERTILIZER OMAN-INDIA FERTILIZER PROJECT PROJECT ((OIF OIF ))

Prepared By: F.P.I Site Representative

Elias H. Takla

TALAL MOUSA (G.E.I REPRESENTATIVE).

Joined the OMIFCO project in March ,2003.Joined the OMIFCO project in March ,2003. Left the project in November, 2003.Left the project in November, 2003.

ELIAS TAKLA (F.P.I REPRESENTATIVE).

Joined the OMIFCO project in May, 2003.Joined the OMIFCO project in May, 2003. Left the project in August, 2004.Left the project in August, 2004.

Snamprogetti . Technip-Snamprogetti . Technip-CoflexipCoflexip

Mr. Michel Aline (Construction Mr. Michel Aline (Construction Manager).Manager).

Mr. Carlo Arconte (Engineering).Mr. Carlo Arconte (Engineering). Mr. Nicolas Desforges (Civil Mr. Nicolas Desforges (Civil

Superintendent).Superintendent). Mr. Chareun Christophe (Utilities).Mr. Chareun Christophe (Utilities).

C.C.C WORK TEAM.C.C.C WORK TEAM. Mr. Bassam Daham (Project Engineer). Jean Choulhi ( Site Senior Surveyor). Sameh R. Omran (Site Engineer). Ziad Ahmad (Site Engineer). Hussain Raóuf Abdul-Samad (General

Foreman). Mustafa Omran (Foreman). 4 Piping Charge Hands. 1 Lamination Charge Hand. 40 Laminators. 35 Pipe Fitters & Pipe Fabricators. 30 Skilled Labors. 25 Unskilled Helpers.

R.T.R.PR.T.R.P. .

INTRODUCTION.INTRODUCTION. COMPOSITION.COMPOSITION. INSTALLATION.INSTALLATION. INSPECTION.INSPECTION. HYDRO-TESTING. HYDRO-TESTING. PROBLEM & ACTION. PROBLEM & ACTION. QUESTIONS AND ANSWERS.QUESTIONS AND ANSWERS. COMMENTS.COMMENTS. PHOTOS.PHOTOS.

NetworksNetworksRTRP pipes are used for the following RTRP pipes are used for the following networks:networks:

Cooling Water Supply & ReturnCooling Water Supply & Return Sea Water Supply & ReturnSea Water Supply & Return Fire Water Fire Water Potable WaterPotable Water ChlorinationChlorination

Some FiguresSome Figures- Cooling Water & Sea Water:- Cooling Water & Sea Water:

Total length 13 kmTotal length 13 km 2000 spools2000 spools Diameter up to 3000 mmDiameter up to 3000 mm

INTRODUCTIONINTRODUCTION (SW & (SW & CW)CW)

FiguresFigures

- - Firefighting Water Network. Total length 8.5 km 1100 Pre-fabricated

spools

- Potable Water Network. Total length 4.5 Km Loose Pipes and

Fittings

INTRODUCTION (FW & INTRODUCTION (FW & PW)PW)

INTRODUCTIONINTRODUCTION

Delivery of Pipes (Pre-Fabricated & Loose Spools) ScheduleDelivery of Pipes (Pre-Fabricated & Loose Spools) Schedule ..

Sea Water & Cooling Water 1st site delivery was on March,2003. Last site delivery was on July,2003.

Fire Water 1st site delivery was on Dec, 2003. Last site delivery was on Jan, 2004.

Potable Water (Loose Pipes and Fittings). 1st site delivery was on Dec, 2003. Last site delivery was on Feb, 2004.

Cont.

INTRODUCTIONINTRODUCTION

Erection of PipesErection of Pipes

Underground Sea Water & Cooling Water Network. 1st site erection was on March,2003. Last site erection was on Feb, 2004.

Fire Water Network. 1st site erection was on Dec, 2003. Last site erection was on August 2004.

Potable Water Network. 1st site erection was on Feb, 2003. Last site erection was on August 2004.

Cont.

COMPOSITIONCOMPOSITION

PipesPipes

Three types of Pipes was used for Three types of Pipes was used for the projectthe project::

GREGRE: Glass Reinforced Epoxy (small : Glass Reinforced Epoxy (small diameters CW, FW, & PW)diameters CW, FW, & PW)

GRPGRP: Glass Reinforced Polyester: Glass Reinforced Polyester Non-Restrained Pipes (SW)Non-Restrained Pipes (SW) Restrained Pipes.(CW, SW)Restrained Pipes.(CW, SW)

GRVGRV: Glass Reinforced Vinyl Ester : Glass Reinforced Vinyl Ester (chlorination) (chlorination)

Lamination Joint on GRP restrained pipe

Jointing

Four types of joints was used in the project:

- Adhesive bonded or Cement (GRE pipes)- Double Bell Coupler (GRP non-restrained)- Lamination (GRP restrained & GRE)- Rubber Seal Lock Joints (Fire Water)

Double Bell Coupler

COMPOSITIONCOMPOSITION

Blind Flanges.Blind Flanges. Carbon Steel Reinforced Blind flanges was Carbon Steel Reinforced Blind flanges was

used for testing (Flat face).used for testing (Flat face).

Gaskets.Gaskets. Rubber with steel inner layer gaskets “Kroll Rubber with steel inner layer gaskets “Kroll

& Ziller” type (diameters up to 2200mm)& Ziller” type (diameters up to 2200mm) EPDM Type (SW).EPDM Type (SW). NBR Type (CW, FW, & PW).NBR Type (CW, FW, & PW). FPM Type (Chlorination).FPM Type (Chlorination).

O-rings rubber type (diameters above O-rings rubber type (diameters above 1800mm)1800mm)

Backfilling.Backfilling. Type of backfill material was taken into Type of backfill material was taken into

account for the pipes design.In Omifco project account for the pipes design.In Omifco project the following materials have been usedthe following materials have been used

SC1 material (20mm aggregates): (diameters SC1 material (20mm aggregates): (diameters above 700mm)above 700mm)

SC2 material (10mm aggregates): (all SC2 material (10mm aggregates): (all diameters)diameters)

“Kroll & Ziller” gaskets

Backfilling with SC1 material

Reinforced C.S Blind Flanges

Cont.

INSTALLATIONINSTALLATION

ExcavationExcavation

Bottom of excavation to be 150mm below the pipe Bottom of excavation to be 150mm below the pipe for bedding Purposes; Minimum trench width to for bedding Purposes; Minimum trench width to be as per sketch.be as per sketch.

Maximum initial deflection (after final backfilling): 2%

Backfilling

Minimum trench width

Dedicated supervision is required for Dedicated supervision is required for compaction on both sides of the pipe to avoid compaction on both sides of the pipe to avoid excess of deflection.When gravels are used , excess of deflection.When gravels are used , the compaction can be done with plate the compaction can be done with plate compactors and concrete vibrators. compactors and concrete vibrators.

INSTALLATIONINSTALLATIONLaminationLamination

Lamination area to be covered.Lamination area to be covered. Ventilation inside pipes to be provided Ventilation inside pipes to be provided

(especially during grinding phase and (especially during grinding phase and Internal lamination task).Internal lamination task).

PPE to be worn.PPE to be worn.

Avg. Progress RatioAvg. Progress Ratio

Number of joints per day with 1 crew (8 people)Number of joints per day with 1 crew (8 people)- Cement joints: 12 joints / day - Cement joints: 12 joints / day - Rubber Seal Lock joints: 15 joints / day- Rubber Seal Lock joints: 15 joints / day- Lamination joints: - Lamination joints:

- >1800mm : 1 joint / day- >1800mm : 1 joint / day- 1200 / 1500 : 4 joints / day- 1200 / 1500 : 4 joints / day- 700 / 1100 : 5 joints / day- 700 / 1100 : 5 joints / day- 450 / 600: 6 joints / day - 450 / 600: 6 joints / day

- Double Bell Coupling Joint : 6 joints / day - Double Bell Coupling Joint : 6 joints / day

Lamination on a restrained pipe Ø3000MM

Double Bell Coupling Joint on a pipe of Ø2000 MM

Cont.

INSPECTIONINSPECTIONJoints InspectionJoints Inspection

Lamination jointsLamination joints Hardness test was applied to the joints after Hardness test was applied to the joints after

24hr from erection by a Barcol tester 24hr from erection by a Barcol tester machine.machine.

Cement JointsCement Joints Visual Inspection.Visual Inspection.

Double Bell Coupler JointsDouble Bell Coupler Joints Visual Inspection.Visual Inspection.

Rubber Seal Lock JointsRubber Seal Lock Joints.. Visual Inspection.Visual Inspection.

Lines InspectionLines Inspection CleaningCleaning Wet cloth with broom stickWet cloth with broom stick Deflection TestDeflection Test Ovality of the pipes to be tested using deflect Ovality of the pipes to be tested using deflect

meter supplied by the vendor.meter supplied by the vendor.

HYDRO-TESTINGHYDRO-TESTING

BackfillingBackfilling Pipes to be backfilled 1m above the pipe crown level and the joints to be Pipes to be backfilled 1m above the pipe crown level and the joints to be

left exposed during the process.left exposed during the process.

Blind FlangesBlind Flanges Carbon Steel Blind Flanges to be used against the RTRP Blank FlangesCarbon Steel Blind Flanges to be used against the RTRP Blank Flanges

DesignDesign C.S blind flanges required thickness is high according to the ASME BPV C.S blind flanges required thickness is high according to the ASME BPV

or TC standards.or TC standards. Reinforcement design to be used to reduce the required thickness as Reinforcement design to be used to reduce the required thickness as

shown in the picture. shown in the picture.

InstallationInstallation Bolts to be tightened by sequence up to defined maximum torque value Bolts to be tightened by sequence up to defined maximum torque value

(depending on gasket type & diameter)(depending on gasket type & diameter)

Thrust blocks (non restrained portions)Thrust blocks (non restrained portions) As the non-restrained pipes do not withstand axial thrust force due to hydrotest As the non-restrained pipes do not withstand axial thrust force due to hydrotest

pressure, thrust blocks have to be installed pressure, thrust blocks have to be installed

PressurizingPressurizing Vents to be provided on every high points. The line has to be vented when Vents to be provided on every high points. The line has to be vented when

starting pressurization.starting pressurization. Stabilization periods to be applied (0.5x & 0.8 x design pressure).Stabilization periods to be applied (0.5x & 0.8 x design pressure). Chart recorded to be used during the activity.Chart recorded to be used during the activity.

CS Blind flange Ø2200 – 80mm thick with reinforcement

Testing pressure: 13.8 bars

Design thickness 200mm

Problem & ActionProblem & Action1.1. Backfill MaterialBackfill Material

Problem DescriptionProblem Description In accordance with project In accordance with project

specifications, SC1 material (as 20mm specifications, SC1 material (as 20mm aggregate) has to be used for bedding aggregate) has to be used for bedding and backfilling of RTRP pipes up to and backfilling of RTRP pipes up to 150 mm above the pipe crown level.150 mm above the pipe crown level.

As about 60,000 m3 of this material As about 60,000 m3 of this material was required and they were not was required and they were not available at site, shortage appear when available at site, shortage appear when backfilling activity started.backfilling activity started.

Actions takenActions taken1.) Client's Engineering approved to use SC2 1.) Client's Engineering approved to use SC2

material (as 10mm aggregates).material (as 10mm aggregates).2.) Crusher plant was mobilized to produce 2.) Crusher plant was mobilized to produce

SC2 material.SC2 material.

Problem & ActionProblem & Action 2.2. Test limitsTest limitsProblem descriptionProblem description On sea water and cooling water On sea water and cooling water

networks, and as per to the lines design, networks, and as per to the lines design, no valves limits are provided. no valves limits are provided.

Actions takenActions taken1.) Lines were extended to as much possible 1.) Lines were extended to as much possible

as to site situation.as to site situation.2.) Temporary spools with flange were used 2.) Temporary spools with flange were used

to divide the lines.to divide the lines.3.) After completion of both tests, short 3.) After completion of both tests, short

spool to be laminated to join the 2 lines spool to be laminated to join the 2 lines (Golden Joints), and those two (Golden Joints), and those two laminations joints will be left exposed laminations joints will be left exposed and to be tested during commissioning and to be tested during commissioning at service test. at service test.

Problem & ActionProblem & Action3.Thrust Blocks3.Thrust BlocksProblem descriptionProblem description As the non-restrained pipes (Double Bell Coupling As the non-restrained pipes (Double Bell Coupling

Joints)do not withstand axial thrust force due to Joints)do not withstand axial thrust force due to hydrotest pressure, thrust blocks have to be installed.hydrotest pressure, thrust blocks have to be installed.

The testing pressure of the sea water supply line is 6 The testing pressure of the sea water supply line is 6 bars and the diameter is 2400mm.bars and the diameter is 2400mm.

The calculations give a thrust block of 420 tons ( 175 The calculations give a thrust block of 420 tons ( 175 m3 of concrete).m3 of concrete).

Actions takenActions taken An addition of 25 to 30 meters of restrained pipes and An addition of 25 to 30 meters of restrained pipes and

Flange with short spool was erected to avoid thrust Flange with short spool was erected to avoid thrust block (height of backfilling above pipes depends on block (height of backfilling above pipes depends on length of restrained portion) length of restrained portion)

Joint Tester

PROBLEM & ACTIONPROBLEM & ACTION 4.4. GasketsGaskets

Problem descriptionProblem description Although CAF asbestos, Neoprene, and Kroll & Ziller non-load Bearing flange joints Although CAF asbestos, Neoprene, and Kroll & Ziller non-load Bearing flange joints

gaskets were used for hydro-testing, but non of them was suitable for RTRP lines as gaskets were used for hydro-testing, but non of them was suitable for RTRP lines as leaks occurred at pressure more than 5 bars.leaks occurred at pressure more than 5 bars.

Actions takenActions taken “ “Kroll & Ziller” gaskets (G-ST-P / OE Flexible design Gasket with Visible Stainless Kroll & Ziller” gaskets (G-ST-P / OE Flexible design Gasket with Visible Stainless

Steel) have been re-ordered by CCC for testing purpose and by Client as permanent Steel) have been re-ordered by CCC for testing purpose and by Client as permanent gaskets.gaskets.

Suggestions for the futureSuggestions for the future Bolts (special length due to particular thickness of RTRP flange) to be included in the Bolts (special length due to particular thickness of RTRP flange) to be included in the

scope of the pipes’ supplier.scope of the pipes’ supplier. Sufficient information about Gaskets (Kroll & Ziller type) DN 1500 and above to be Sufficient information about Gaskets (Kroll & Ziller type) DN 1500 and above to be

indicated in the installation manual.indicated in the installation manual.

PROBLEM & ACTIONPROBLEM & ACTION Backfill of joints after hydrotestBackfill of joints after hydrotest

QuestionQuestion: Joints have been left exposed for the hydrotest in doing “walls” with : Joints have been left exposed for the hydrotest in doing “walls” with gravel bags all-around. These “walls” can reach 4m high. Can these bags remain in gravel bags all-around. These “walls” can reach 4m high. Can these bags remain in the trench ?the trench ?

Answer: Answer: gravel bags can remain in the trench provided the presence of these bags is gravel bags can remain in the trench provided the presence of these bags is not affecting the backfilling of the joints. not affecting the backfilling of the joints.

Thrust block for restrained portionsThrust block for restrained portions Question:Question: is thrust block required for the hydrotest of restrained portions ? is thrust block required for the hydrotest of restrained portions ? Answer:Answer: Thrust blocks are not required for restrained lines. However, an anchor Thrust blocks are not required for restrained lines. However, an anchor

block to support the tests blind flange (same width and height of the blind flange) block to support the tests blind flange (same width and height of the blind flange) has to be used for safety reason.has to be used for safety reason.

Testing method statementTesting method statement Question: What is the testing method statement to follow for all RTRP lines ?Question: What is the testing method statement to follow for all RTRP lines ? Answer: After necessary venting:Answer: After necessary venting:

Raise the pressure to 0.5 x design pressure with half hour stabilizationRaise the pressure to 0.5 x design pressure with half hour stabilization Raise the pressure to 0.8 x design pressure with half hour stabilizationRaise the pressure to 0.8 x design pressure with half hour stabilization Raise the pressure to final testing pressure and maintain for 2 to 3 hours Raise the pressure to final testing pressure and maintain for 2 to 3 hours

to permit inspection of all jointsto permit inspection of all joints On Omifco project, when joints have been backfilled before hydrotest due to On Omifco project, when joints have been backfilled before hydrotest due to

access issue, the pressure is then lowered to 0.8 x testing pressure and access issue, the pressure is then lowered to 0.8 x testing pressure and maintained for 10 hours, with use of chart recorder.maintained for 10 hours, with use of chart recorder.

QUESTION AND ANSWERQUESTION AND ANSWER Leak on couplersLeak on couplers

Question:Question: what to do in case of leak on a double bell coupler joint ? what to do in case of leak on a double bell coupler joint ? Answer: Answer: The couplers should not been replaced with lamination.The couplers should not been replaced with lamination.

• Cut a ring (1.5m) from one of the two assembled pipesCut a ring (1.5m) from one of the two assembled pipes• Pull out the pipe from couplerPull out the pipe from coupler• Remove the coupler and change the gasketsRemove the coupler and change the gaskets• Re-mount the couplerRe-mount the coupler• Re-fix the pipe sectionRe-fix the pipe section• Insert the cut ringInsert the cut ring• Laminate the ring to the pipe sectionLaminate the ring to the pipe section

Maximum torque valueMaximum torque value Question:Question: what are the maximum torque values for “Kroll & Ziller” gaskets & O-rings ? what are the maximum torque values for “Kroll & Ziller” gaskets & O-rings ? Answer:Answer: maximum torque value for “Kroll & Ziller” gaskets are (ASA standard): maximum torque value for “Kroll & Ziller” gaskets are (ASA standard):

• < Ø 300: 50 Nm< Ø 300: 50 Nm• Ø350 to Ø600: 100 NmØ350 to Ø600: 100 Nm• Ø700 to Ø800: 150 NmØ700 to Ø800: 150 Nm• Ø900 to Ø1400: 200 NmØ900 to Ø1400: 200 Nm• > Ø 1800: 250 Nm.> Ø 1800: 250 Nm.• Maximum torque value for O-rings: 100 NmMaximum torque value for O-rings: 100 Nm

Shelf life of lamination kitsShelf life of lamination kits Question:Question: What is the shelf life of the resin for the lamination kits ? What is the shelf life of the resin for the lamination kits ? Answer:Answer: Resin can be used until its viscosity is affected due to longer storage period. (to be confirmed by Resin can be used until its viscosity is affected due to longer storage period. (to be confirmed by

site representative)site representative)

G.E.I.G.E.I. Spools numbering Contradiction.Spools numbering Contradiction. There were no home lines highlighted on the non-restrained pipes to show There were no home lines highlighted on the non-restrained pipes to show

where is the coupler limit.where is the coupler limit. Late spools delivery.Late spools delivery. Some pre-fabricated spools were not as same as shown in the isometrics.Some pre-fabricated spools were not as same as shown in the isometrics. Late answers for our inquiries according to site situation.Late answers for our inquiries according to site situation.

DynaFlow “Engineering”.DynaFlow “Engineering”. While designing, Venting were not taken in consideration.While designing, Venting were not taken in consideration. Test limits were not taken in consideration, i.e. for non-restrained pipes Test limits were not taken in consideration, i.e. for non-restrained pipes

plain end were fabricated rather than double-bell coupler end “Wear plain end were fabricated rather than double-bell coupler end “Wear Box”.Box”.

Late answers for our inquiries.Late answers for our inquiries. Revised drawing were sent after when lines’ installation and testing are Revised drawing were sent after when lines’ installation and testing are

accomplished.accomplished.

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