OMAN-INDIA FERTILIZER

PROJECT (OIF )

OMIFCO
SUR – SULTANATE OF OMAN

Prepared By: F.P.I Site Representative

Elias H. Takla
 TALAL MOUSA (G.E.I REPRESENTATIVE).

 Joined the OMIFCO project in March ,2003.

 Left the project in November, 2003.

 ELIAS TAKLA (F.P.I REPRESENTATIVE).

 Joined the OMIFCO project in May, 2003.

 Left the project in August, 2004.
 Snamprogetti . Technip-Coflexip

 Mr. Michel Aline (Construction Manager).

 Mr. Carlo Arconte (Engineering).
 Mr. Nicolas Desforges (Civil Superintendent).
 Mr. Chareun Christophe (Utilities).
 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.P.
 INTRODUCTION.
 COMPOSITION.
 INSTALLATION.
 INSPECTION.
 HYDRO-TESTING.
 PROBLEM & ACTION.
 QUESTIONS AND ANSWERS.
 COMMENTS.
 PHOTOS.
INTRODUCTION (SW & CW)
Networks
RTRP pipes are used for the following
networks:
 Cooling Water Supply & Return
 Sea Water Supply & Return
 Fire Water
 Potable Water
 Chlorination

Some Figures
- Cooling Water & Sea Water:
 Total length 13 km
 2000 spools
 Diameter up to 3000 mm
INTRODUCTION (FW & PW)
Figures

- 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

Delivery 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.
INTRODUCTION

Erection 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.
 COMPOSITION
Pipes

Three types of Pipes was used for the project :

 GRE: Glass Reinforced Epoxy (small

diameters CW, FW, & PW)
 GRP: Glass Reinforced Polyester
 Non-Restrained Pipes (SW)

 Restrained Pipes.(CW, SW)

Lamination Joint on
 GRV: Glass Reinforced Vinyl Ester GRP restrained pipe
(chlorination)

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) Double Bell Coupler
- Rubber Seal Lock Joints (Fire Water)
COMPOSITION
Blind Flanges.
Carbon Steel Reinforced Blind flanges was used
for testing (Flat face).
Gaskets.
 Rubber with steel inner layer gaskets “Kroll &
Ziller” type (diameters up to 2200mm)
 EPDM Type (SW).

 NBR Type (CW, FW, & PW).

 FPM Type (Chlorination).

 O-rings rubber type (diameters above 1800mm) “Kroll & Ziller” gaskets Reinforced C.S Blind Flanges
Backfilling.
Type of backfill material was taken into account
for the pipes design.In Omifco project the
following materials have been used
 SC1 material (20mm aggregates): (diameters
above 700mm)
 SC2 material (10mm aggregates): (all
diameters)

Backfilling with SC1 material

Cont.
INSTALLATION
Excavation

Bottom of excavation to be 150mm below the pipe

for bedding Purposes; Minimum trench width to be
as per sketch.

Minimum trench width

Backfilling

Dedicated supervision is required for

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

Maximum initial deflection (after final

backfilling): 2%
 INSTALLATION
Lamination
 Lamination area to be covered.
 Ventilation inside pipes to be provided
(especially during grinding phase and
Internal lamination task).
 PPE to be worn.

 Avg. Progress Ratio Lamination on a restrained pipe Ø3000MM

Number of joints per day with 1 crew (8 people)

- Cement joints: 12 joints / day
- Rubber Seal Lock joints: 15 joints / day
- Lamination joints:
- >1800mm : 1 joint / day
- 1200 / 1500 : 4 joints / day
- 700 / 1100 : 5 joints / day
- 450 / 600: 6 joints / day
- Double Bell Coupling Joint : 6 joints / day
Double Bell Coupling Joint on a pipe of Ø2000 MM

Cont.
 INSPECTION
Joints Inspection

Lamination joints
 Hardness test was applied to the joints after
24hr from erection by a Barcol tester
machine.
Cement Joints
 Visual Inspection.
Double Bell Coupler Joints
 Visual Inspection.
Rubber Seal Lock Joints.
 Visual Inspection.

Lines Inspection
 Cleaning
Wet cloth with broom stick
 Deflection Test
Ovality of the pipes to be tested using deflect
meter supplied by the vendor.
 HYDRO-TESTING
Backfilling
Pipes to be backfilled 1m above the pipe crown level and the joints to be left
exposed during the process.
Blind Flanges
Carbon Steel Blind Flanges to be used against the RTRP Blank Flanges
 Design
 C.S blind flanges required thickness is high according to the ASME BPV or
TC standards.
 Reinforcement design to be used to reduce the required thickness as shown
in the picture.

 Installation
Bolts to be tightened by sequence up to defined maximum torque value (depending
on gasket type & diameter)

Thrust blocks (non restrained portions)

As the non-restrained pipes do not withstand axial thrust force due to hydrotest CS Blind flange Ø2200 – 80mm thick
pressure, thrust blocks have to be installed
with reinforcement
Pressurizing
 Vents to be provided on every high points. The line has to be vented when starting Testing pressure: 13.8 bars
pressurization.
 Stabilization periods to be applied (0.5x & 0.8 x design pressure). Design thickness 200mm
 Chart recorded to be used during the activity.
Problem & Action
1. Backfill Material
Problem Description
In accordance with project
specifications, SC1 material (as 20mm
aggregate) has to be used for bedding
and backfilling of RTRP pipes up to 150
mm above the pipe crown level.
As about 60,000 m3 of this material was
required and they were not available at
site, shortage appear when backfilling
activity started.

Actions taken
1.) Client's Engineering approved to use SC2
material (as 10mm aggregates).
2.) Crusher plant was mobilized to produce SC2
material.
Problem & Action
2. Test limits
Problem description
On sea water and cooling water
networks, and as per to the lines design,
no valves limits are provided.
Actions taken
1.) Lines were extended to as much possible
as to site situation.
2.) Temporary spools with flange were used
to divide the lines.
3.) After completion of both tests, short
spool to be laminated to join the 2 lines
(Golden Joints), and those two
laminations joints will be left exposed
and to be tested during commissioning
at service test.
Problem & Action
3.Thrust Blocks
Problem description
As the non-restrained pipes (Double Bell Coupling
Joints)do not withstand axial thrust force due to
hydrotest pressure, thrust blocks have to be installed.
The testing pressure of the sea water supply line is 6
bars and the diameter is 2400mm.
The calculations give a thrust block of 420 tons ( 175
m3 of concrete).

Actions taken
An addition of 25 to 30 meters of restrained pipes and Joint Tester
Flange with short spool was erected to avoid thrust
block (height of backfilling above pipes depends on
length of restrained portion)
PROBLEM & ACTION
4. Gaskets
Problem description
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
leaks occurred at pressure more than 5 bars.

Actions taken
“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
gaskets.

Suggestions for the future

Bolts (special length due to particular thickness of RTRP flange) to be included in the
scope of the pipes’ supplier.
Sufficient information about Gaskets (Kroll & Ziller type) DN 1500 and above to be
indicated in the installation manual.
PROBLEM & ACTION
 Backfill of joints after hydrotest
 Question: 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 the
trench ?
 Answer: gravel bags can remain in the trench provided the presence of these bags is not
affecting the backfilling of the joints.

 Thrust block for restrained portions

 Question: is thrust block required for the hydrotest of restrained portions ?
 Answer: 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) has to be
used for safety reason.

 Testing method statement

 Question: What is the testing method statement to follow for all RTRP lines ?
 Answer: After necessary venting:
 Raise the pressure to 0.5 x design pressure with half hour stabilization
 Raise 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 to
permit inspection of all joints
 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 maintained
for 10 hours, with use of chart recorder.
QUESTION AND ANSWER
 Leak on couplers
 Question: what to do in case of leak on a double bell coupler joint ?
 Answer: The couplers should not been replaced with lamination.
• Cut a ring (1.5m) from one of the two assembled pipes
• Pull out the pipe from coupler
• Remove the coupler and change the gaskets
• Re-mount the coupler
• Re-fix the pipe section
• Insert the cut ring
• Laminate the ring to the pipe section
 Maximum torque value
 Question: what are the maximum torque values for “Kroll & Ziller” gaskets & O-rings ?
 Answer: maximum torque value for “Kroll & Ziller” gaskets are (ASA standard):
• < Ø 300: 50 Nm
• Ø350 to Ø600: 100 Nm
• Ø700 to Ø800: 150 Nm
• Ø900 to Ø1400: 200 Nm
• > Ø 1800: 250 Nm.
• Maximum torque value for O-rings: 100 Nm
 Shelf life of lamination kits
 Question: What is the shelf life of the resin for the lamination kits ?
 Answer: Resin can be used until its viscosity is affected due to longer storage period. (to be confirmed by site
representative)
Comments
 G.E.I.
 Spools numbering Contradiction.
 There were no home lines highlighted on the non-restrained pipes to show
where is the coupler limit.
 Late spools delivery.
 Some pre-fabricated spools were not as same as shown in the isometrics.
 Late answers for our inquiries according to site situation.

 DynaFlow “Engineering”.
 While designing, Venting were not taken in consideration.
 Test limits were not taken in consideration, i.e. for non-restrained pipes
plain end were fabricated rather than double-bell coupler end “Wear
Box”.
 Late answers for our inquiries.
 Revised drawing were sent after when lines’ installation and testing are
accomplished.